Chevrolet - Cavalier - Workshop Manual - 1991 - 1991

Factory Workshop Manual Make Chevrolet Model Cavalier Engine and year Cavalier-Z24 L4-134 2.2L (1991) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 12 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 13 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 14 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 20 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 21 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 22 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Engine Component Locations. LH Front Of Engine Compartment Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 27 Radiator Cooling Fan Motor Relay: Description and Operation Wiring Diagram For Cooling Fan The ECM controls the engine coolant fan relay under several operating conditions. If the coolant temperature sensor indicates high engine temperature, the ECM will energize the relay to turn "ON" the fan. If the A/C is engaged, the ECM will turn the coolant fan on to cool the condenser as well as the radiator. Some fault codes will cause the ECM to turn on the fan. Above certain vehicle speeds, the ECM will de-energize the fan relay since at higher road speeds there is ample air flow. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Behind LH Side Of I/P, Near Top Of Shroud Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 32 Cruise Control Module: Description and Operation The module will interpret the position of the servo, the position of the control switches and the output of the speed sensor. In response to these inputs, the module electrically signals the opening or closing of the vent and vacuum solenoid valves in the servo. The module is mounted on the dash support bracket at the right side of the steering column, but is integral with the ECM on some models with certain engines. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations LH Front Of Dash, On Relay Bracket Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations RH Side Of Engine Compartment. RH Rear Of Engine Compartment, Behind Strut Tower Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 40 Compressor Clutch Relay: Description and Operation Wiring Diagram For A/C Clutch Control The ECM controls the A/C compressor clutch relay. When the A/C is turned on, the ECM delays the clutch engagement to allow the IAC valve to raise the engine idle speed to compensate for the added load. The ECM allows the relay to disengage the A/C clutch at wide open throttle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > Customer Interest for A/T Shift Indicator Module: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned A/T Shift Indicator Module: Customer Interest A/T - Shift Indicator Misaligned Number: 91-458-7A Section: 7A Date: DEC. 1991 Corporate Bulletin No.: 138305 ASE No.: A2 Subject: SHIFT INDICATOR MISALIGNED Model and Year: 1991 CAVALIER WITH AUTOMATIC TRANSMISSION Condition: Shift indicator may come out of adjustment. Cause: Adjuster did not "collapse" on indicator tape during production, thus creating a low ratcheting effort. Correction: Replace console trim plate with updated part. Refer to "Parts Information" for updated part number. Refer to Section 8C for replacement procedure. Parts Information: 22575236 Trim plate assembly - with power windows 22575237 Trim plate assembly - without power windows Parts are currently available from GMSPO. Warranty Information: Labor Operation Number: K5100 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/T Shift Indicator Module: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned A/T Shift Indicator Module: All Technical Service Bulletins A/T - Shift Indicator Misaligned Number: 91-458-7A Section: 7A Date: DEC. 1991 Corporate Bulletin No.: 138305 ASE No.: A2 Subject: SHIFT INDICATOR MISALIGNED Model and Year: 1991 CAVALIER WITH AUTOMATIC TRANSMISSION Condition: Shift indicator may come out of adjustment. Cause: Adjuster did not "collapse" on indicator tape during production, thus creating a low ratcheting effort. Correction: Replace console trim plate with updated part. Refer to "Parts Information" for updated part number. Refer to Section 8C for replacement procedure. Parts Information: 22575236 Trim plate assembly - with power windows 22575237 Trim plate assembly - without power windows Parts are currently available from GMSPO. Warranty Information: Labor Operation Number: K5100 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations LH Front Corner Of Engine Compartment LH front corner of engine compartment Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay To Convenience Center Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Locations > Lamp Dimmer Module I/P Harness To Turns Signal Flasher & Lamp Dimmer Module Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Locations > Lamp Dimmer Module > Page 66 Behind LH Side Of I/P Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 73 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 74 Engine Control Module: Technical Service Bulletins ECM/PCM - Damage Prevention Number: 91-318-6E Section: 6E Date: MAY 1991 Corp. Bulletin No.: 176502R Subject: DAMAGE TO ECM/PCM CIRCUIT BOARD WHEN INSTALLING A MEM-CAL Model and Year: 1986-91 ALL PASSENGER CARS AND TRUCKS CONDITION: When installing a service replacement ECM/PCM, the use of incorrect MEMCAL installation procedures may cause the ECM/PCM to fail before it can be installed in the vehicle. This condition may appear as if the ECM/PCM were defective when it was shipped to the dealership, when in fact it was damaged while being installed. In addition this condition may also occur when installing an "updated" service MEM-CAL into the vehicles original equipment ECM/PCM. CAUSE: Excessive vertical force may be applied to the MEM-CAL resulting in flexing of the circuit board and damage to the connections between the circuit board and attached components. Excessive verticle force may be generated in two ways. 1. Incorrect MEM-CAL installation procedure. 2. Interference between MEM-CAL and cover. CORRECTION: Use the following procedure. Service Procedure: Important: This procedure supersedes any instructions regarding MEM-CAL installation dated prior to September 1990. 1. Inspect the MEM-CAL to determine if a cork spacer is glued to the top side of the MEM-CAL assembly. If so, remove it prior to installation. 2. Align small notches with matching notches in the ECM/PCM MEM-CAL socket. 3. VERY GENTLY press down on the ends of the MEM-CAL until the locking levers are rotated toward the sides of the MEM-CAL. Notice: To avoid ECM/PCM damage, do not press on the ends of the MEM-CAL until the levers snap into place. Do not use any vertical force beyond the minimum required to engage the MEM-CAL into its socket. 4. While continuing light pressure on the ends of MEM-CAL, use your index fingers to press the locking levers inward until they are snapped into place. Listen for click. 5. Install MEM-CAL cover and install ECM/PCM in vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 75 Engine Control Module: Technical Service Bulletins ECM/PCM - Damaged and/or Misdiagnosed Number: 91-384-6E Section: 6E Date: AUGUST 1991 Corporate Bulletin No.: 176503 Subject: DAMAGED ECM/PCM AND/OR MIS-DIAGNOSED ECM/PCM SYMPTOMS DUE TO INCORRECT "TAP-TESTING" PROCEDURES Model and Year: 1982-91 ALL PASSENGER CARS AND TRUCKS CONDITION: Because of the intermittent nature of some Electronic Control Module (ECM) or Powertrain Control Modules (PCM) symptoms, some service technicians have been subjecting the ECM/PCM to vibration and/or shock testing. Commonly known as tap-testing, this procedure involves tapping on the ECM/PCM case, while the engine is running. It is generally accepted that if the engine or ECM/PCM falters due to the tapping, an intermittent internal ECM/PCM defect may be indicated. However, this may not always be true. If too much force is applied to the ECM/PCM during the test the following symptoms may result: ^ Immediate ECM/PCM failure. ^ ECM/PCM suffers damage which may cause a failure at a later date. ^ ECM/PCM Reset (or Glitch), creating a momentary stall, miss Service Engine Soon (SES) light and/or loss of serial data. CAUSE: The ECM/PCM should be tapped using only the fingertips of one hand. Use of the palm, fist, or any type of tool subjects the ECM/PCM to forces that can cause both the circuit board and the outer aluminum case to flex and distort beyond design limits. The Integrated Circuits (IC) used in today's ECM/PCMs are mounted to the circuit board using a mounting process referred to as "surface technology." There are no circuit board holes for IC leads to go through. The IC leads set on pads, (28 pads or 52 pads depending on the IC) and solder is flowed around the leads to make the electrical connection to the circuit board. ^ Any flexing of the circuit board, beyond design limits, places the IC solder connections at risk of damage. Such damage may be apparent immediately, or it may appear at a future date. Circuit board deflection can occur as a result of striking the ECM/PCM, using ONLY THE PALM OF THE HAND. ^ If struck on the bottom side (the side opposite the service label), the ECM/PCM's aluminum outer case may deflect inward far enough to contact the electrical leads attached to the circuit board. Once in contact with the case the ECM/PCM electrical components will be shorted directly to ground. Although such shorting certainly has the potential to damage the ECM/PCM, it may not be permanent damage, depending on which circuit is involved. However, even if permanent damage is avoided, a short on any of the circuits will cause a disruption of normal ECM/PCM operation for the instant that the short occurs. This disruption may cause the ECM/PCM to reset (see "reset" above), creating the false impression that it is vibration sensitive or faulty. Reset is the ECM/PCM's normal way of coping with large voltage spikes. An ECM/PCM reset does not indicate that the ECM/PCM is defective or faulty, only that it is being subjected to abnormal conditions. CORRECTION: 1. TAP THE ECM/PCM ONLY ON THE TOP SIDE (The top side is where the service label is located.) ^ This will minimize the chance of deflecting the ECM/PCM case into the electrical leads on the circuit board. The clearance between the case and the circuit board is closest on the bottom side of the ECM/PCM. 2. TAP THE ECM/PCM USING ONLY THE FINGERTIPS - NO TOOLS. ^ To avoid excessive case deflection, avoid tapping in the center of the case. Tapping close to the edge of the ECM/PCM, especially in the corners, is best. ^ While using greater force may seem more effective, the test itself may cause the ECM/PCM to fail. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications Engine Control Module: Specifications Computer Terminal Voltage Specifications ECM Connector Terminal End View WIRE COLOR ABBREVIATION BLACK BLK Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 78 BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 79 Engine Control Module: Specifications ECM Terminal Identification & Voltage Specifications ECM Connector Terminal End View WIRE COLOR ABBREVIATION BLACK BLK Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 80 BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 81 ECM Connector Terminal End View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications > Page 82 ECM Located In Passenger Compartment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications > Page 83 ECM Connector Terminal End View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Electronic Control Module (ECM) Engine Control Module: Description and Operation Electronic Control Module (ECM) Closed Loop Operation ECM And PROM Access Cover The Electronic Control Module (ECM) is located in the passenger compartment and is the control center of the Computer Command Control (C3) system. The ECM constantly receives information from various sensors. The computer performs the diagnostic functions of the system. The computer can recognize operational problems and alert the driver through the "SERVICE ENGINE SOON" light. The computer stores a trouble code which identifies the problem area to diagnose and repair. The computer is designed to process the various input information, and send the necessary electrical response to control fuel delivery, spark control, and other emission control systems. The computer used in these vehicles is a type called GMP4. The computer can control these devices through the use of Quad Driver Modules (QDM). When the ECM is commanding a device or a component "ON," the voltage potential of the output is "LOW" or near zero volts. When the ECM is commanding a device or component "OFF," the voltage potential of the circuit will be "HIGH," or near 12 volts. The primary function of the QDM is to supply the ground for the component being controlled. The input information has an interrelation between sensor output. If one of the input devices failed, such as the oxygen sensor, this could affect more than one of the systems controlled by the computer. The computer has a learning ability which allows it to make corrections for minor variations in the fuel system to improve driveability. If the battery is disconnected to clear trouble codes or for repair, the learning process has to begin all over again, and a change may be noticed in the driving performance of the vehicle. To reset the vehicles learning ability, make sure the engine is at operating temperature and operate the vehicle at part throttle, moderate acceleration, and idle conditions, until normal performance returns. The ECM used in these vehicles uses an ECM with two serviceable parts. A controller called a ECM, without a PROM, and a PROM with specific programming information. NOTE: When a production ECM is replaced with a service ECM, it is important to transfer the broadcast code and production number from the original ECM to the service ECM. This allows for positive identification of ECM parts throughout the service life of the vehicle. DO NOT affix the information to the ECM cover. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Electronic Control Module (ECM) > Page 86 Engine Control Module: Description and Operation Throttle Body Fuel Injection Control Modules Powertrain Control Module (PCM) The Electronic Control Module (ECM) is located in the passenger compartment and is the control center of the Computer Command Control (C3) system. The ECM constantly receives information from various sensors. The computer performs the diagnostic functions of the system. The computer can recognize operational problems and alert the driver through the "SERVICE ENGINE SOON" light. The computer stores a trouble code which identifies the problem area to diagnose and repair. The computer is designed to process the various input information, and send the necessary electrical response to control fuel delivery, spark control, and other emission control systems. The computer can control these devices through the use of Quad Driver Modules (QDM). When the ECM is commanding a device or a component "ON," the voltage potential of the output is "LOW" or near zero volts. When the ECM is commanding a device or component "OFF," the voltage potential of the circuit will be "HIGH," or near 12 volts. The primary function of the QDM is to supply the ground for the component being controlled. The input information has an interrelation between sensor output. If one of the input devices failed, such as the oxygen sensor, this could affect more than one of the systems controlled by the computer. The computer has a learning ability which allows it to make corrections for minor variations in the fuel system to improve driveability. If the battery is disconnected to clear trouble codes or for repair, the learning process has to begin all over again, and a change may be noticed in the driving performance of the vehicle. To reset the vehicles learning ability, make sure the engine is at operating temperature and operate the vehicle at part throttle, moderate acceleration, and idle conditions, until normal performance returns. A vehicle equipped with a 4-cylinder engine has an ECM referred to as GMP4 with two parts for service. A controller which is the ECM itself, without a MEM-CAL, and a memory calibration unit called a MEM-CAL (PROM). Vehicles with a V-6 or V-8 cylinder engine have an ECM referred to as GMCM with three serviceable parts. A controller called a ECM, without a PROM, a PROM with specific programming information, and a CAL-PAK with specific engine specifications. NOTE: When a production ECM is replaced with a service ECM, it is important to transfer the broadcast code and production number from the original ECM to the service ECM. This allows for positive identification of ECM parts throughout the service life of the vehicle. DO NOT affix the information to the ECM cover. C3 Self Diagnostics ALDL Connector Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Electronic Control Module (ECM) > Page 87 Use a "Scan" tool or ground the diagnostic test terminal with the engine not running and the ignition switch in the "ON" position in order to retrieve codes. The "SERVICE ENGINE SOON" light will flash a Code 12 three times and then flash each code stored in memory three times, if the "Scan" tool is not used. Once all Codes are retrieved, a Code 12 will follow. New codes cannot be stored in the ECM once the diagnostics mode is activated. See DIAGNOSTIC CIRCUIT CHECK for a complete system check. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics Some control module's may have problems due to cracked solder joints on the circuit board. These internal control module problems can cause the following symptoms: ^ Failure to start or vehicle is stalling. ^ The "CHECK ENGINE" "SERVICE ENGINE SOON" or "MALFUNCTION INDICATOR" light will flash or light up, but no trouble codes will be present. ^ Vehicle instrument panel displays may be inoperative. ^ The control module may or may not communicate with the scanner. ^ Other intermittent driveability problems. Incorrect PROM or MEMCAL removal and replacement can create solder joint problems or aggravate an existing condition. See PROM or MEMCAL INSTALLATION for proper procedures. If a solder joint problem results in a "hard" failure, normal test procedures will usually pinpoint a faulty control module. Many symptoms caused by poor solder joints in the control module result in intermittent problems, but they may be hard to duplicate during troubleshooting. Control module's with solder joint problems are sensitive to heat and vibration. You can check for these internal control module problems in either, or both, of the following ways: ^ Remove the control module from its mounting bracket and extend it on the harness so that you can expose it to the vehicle heater ducts. Alternatively, use flexible ducting to route air from the heater to the control module location. Then run the engine and operate the heater at the "MAX HEAT" position. This exposes the control module to approximately 140°F. ^ With the engine running, tap on the control module several times with your hand or finger tips to simulate vehicle vibration. If the engine stumbles or stalls, the "CHECK ENGINE" "SERVICE ENGINE SOON" or "MALFUNCTION INDICATOR" light flashes, or any of the previous symptoms occur, the control module may have bad solder joints on the circuit board. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) Replacement Engine Control Module: Service and Repair Engine Control Module (ECM) Replacement ECM Located In Passenger Compartment. ECM And PROM Access Cover Prom Removal And Tool Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) Replacement > Page 92 When replacing a production ECM with a service ECM, transfer the broadcast code and production number from the production unit to the service unit. Also, during replacement, the PROM must be removed from the ECM being replaced and transferred to the new unit. Some ECM's are equipped with another chip called a Cal-Pak. If the ECM if equipped with a Cal-Pak chip, it will be located next to the PROM and must be transferred along with the PROM. 1. Disconnect battery ground cable. 2. Then disconnect two computer electrical connectors. 3. Remove computer mounting hardware. 4. Remove computer from passenger compartment. 5. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) Replacement > Page 93 Engine Control Module: Service and Repair Throttle Body Fuel Injection ECM Replacement When replacing a production ECM with a service ECM, transfer the broadcast code and production number from the production unit to the service unit. Also, during replacement, the PROM, CALPACK and if equipped, the MEMCAL must be removed from the ECM being replaced and transferred to the new unit. Refer to PROM, CALPAK, and MEMCAL for procedures. 1. Disconnect battery ground cable. 2. Then disconnect computer electrical connectors. 3. Remove computer mounting hardware. 4. Remove computer from passenger compartment. 5. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay And In-line Fuse. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 98 Fuel Pump Relay: Description and Operation Wiring Diagram For Fuel Pump Relay When the key is first turned ON, without the engine running, the ECM will turn the fuel pump relay ON for two seconds. This builds up the fuel pressure to normal operating pressure. If the engine is not started within two seconds, the ECM will shut the fuel pump OFF and wait until ignition reference pulses are present. As soon as the engine is cranked, the ECM turns the relay ON, which powers the fuel pump. The ECM continues to power the fuel pump during engine operation. If the fuel pump relay fails, it is backed up by the oil pressure switch, which continues to operate the fuel pump as long as oil pressure remains above 28.0 kPa (4 psi). - A faulty fuel pump relay can result in long cranking times, particularly if the engine is cold. - An inoperative fuel pump would cause a no start condition. A fuel pump which does not provide enough pressure can result in poor performance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 99 Fuel Pump Relay: Testing and Inspection Wiring Diagram For Fuel Pump Relay When the key is first turned ON, without the engine running, the ECM will turn the fuel pump relay ON for two seconds. This builds up the fuel pressure to normal operating pressure. If the engine is not started within two seconds, the ECM will shut the fuel pump OFF and wait until ignition reference pulses are present. As soon as the engine is cranked, the ECM turns the relay ON, which powers the fuel pump. The ECM continues to power the fuel pump during engine operation. If the fuel pump relay fails, it is backed up by the oil pressure switch, which continues to operate the fuel pump as long as oil pressure remains above 28.0 kPa (4 psi). - A faulty fuel pump relay can result in long cranking times, particularly if the engine is cold. - An inoperative fuel pump would cause a no start condition. A fuel pump which does not provide enough pressure can result in poor performance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 100 Fuel Pump Relay: Service and Repair Fuel Pump Relay And In-line Fuse. NOTE: The fuel pump relay is located in the engine compartment, attached to the relay bracket mounted on the dash. Other than checking for loose connections the only service on the fuel pump relay is replacement. PROCEDURE 1. Verify that the ignition switch is in the "OFF" position. 2. Disconnect the wiring harness plug. 3. Remove the fuel pump relay. 4. Install the new fuel pump relay. 5. Connect the wiring harness plug securely. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set Ignition Control Module: Customer Interest Engine - Stalls/No Start/Runs Rough/Code 42 Set Number: 91-453-6D Section: 6D Date: NOV. 1991 Corporate Bulletin No.: 136405 ASE No.: A6, A8 Subject: INTERMITTENT DIAGNOSTIC TROUBLE CODE 42 AND/OR DRIVEABILITY Model and Year: 1990-91 CAVALIER, CORSICA AND BERETTA WITH 2.2L ENGINE Condition: Some 1990-91 J and L vehicles equipped with the 2.2L (LM3) engine may intermittently exhibit one or more of the following conditions: * ECM Diagnostic Trouble Code 42 set, with no trouble found. * Engine stalling rough running, with no trouble found. * Intermittent no-start, with no trouble found. * ECM fuse blown, with no trouble found. Cause: DIS (Ignition) module lead wiring may be subject to a rub-through condition at the engine wiring harness bracket where it is mounted at the transaxle case. In addition, a similar condition may also exist on the transaxle case near the same location, from a sharp edge formed during case casting, when equipped with manual transaxle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 110 Correction: Refer to Illustrations for location of repairs. Repair Procedure: - Remove secondary ignition wire bracket and wires, set aside. - Remove clutch cable retainer and cables, set aside. (Manual transaxle only.) - Un-clip engine wiring harness conduit from retainer, pull back conduit to expose harness. - Using common "black" electrical tape (locally attained part), begin taping approximately 5 inches back from the point where the main harness breaks out into 3 smaller harnesses. - While taping to the break-out point, push the individual smaller conduits back and tape up the harnesses as far as possible. * IMPORTANT: Tape wire harness with 4 layers of tape to insure proper insulation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 111 * IMPORTANT: If any wires are worn through enough to short out against each other, if strands of wire are broken, or if an "open" wiring condition is found, refer to Section 8A of the applicable Service Manual for proper wiring repair. - Install wiring harness back into conduit. Before clipping retainer closed, pull the harness towards the center of the vehicle to remove any slack in the harness. This will keep the harness off the transaxle case and away from the transaxle controls. - Clip harness retainer into position. - Reinstall clutch cables and retainer. (Manual transaxle only). - Reinstall secondary ignition cables and bracket. Warranty and Labor Time Information: For taping and repositioning harness: Labor Code: T1789 Labor Time: 0.3 Hours For wiring repair, taping and repositioning of harness: Labor Code: T1789 Labor Time 0.4 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set Ignition Control Module: All Technical Service Bulletins Engine - Stalls/No Start/Runs Rough/Code 42 Set Number: 91-453-6D Section: 6D Date: NOV. 1991 Corporate Bulletin No.: 136405 ASE No.: A6, A8 Subject: INTERMITTENT DIAGNOSTIC TROUBLE CODE 42 AND/OR DRIVEABILITY Model and Year: 1990-91 CAVALIER, CORSICA AND BERETTA WITH 2.2L ENGINE Condition: Some 1990-91 J and L vehicles equipped with the 2.2L (LM3) engine may intermittently exhibit one or more of the following conditions: * ECM Diagnostic Trouble Code 42 set, with no trouble found. * Engine stalling rough running, with no trouble found. * Intermittent no-start, with no trouble found. * ECM fuse blown, with no trouble found. Cause: DIS (Ignition) module lead wiring may be subject to a rub-through condition at the engine wiring harness bracket where it is mounted at the transaxle case. In addition, a similar condition may also exist on the transaxle case near the same location, from a sharp edge formed during case casting, when equipped with manual transaxle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 117 Correction: Refer to Illustrations for location of repairs. Repair Procedure: - Remove secondary ignition wire bracket and wires, set aside. - Remove clutch cable retainer and cables, set aside. (Manual transaxle only.) - Un-clip engine wiring harness conduit from retainer, pull back conduit to expose harness. - Using common "black" electrical tape (locally attained part), begin taping approximately 5 inches back from the point where the main harness breaks out into 3 smaller harnesses. - While taping to the break-out point, push the individual smaller conduits back and tape up the harnesses as far as possible. * IMPORTANT: Tape wire harness with 4 layers of tape to insure proper insulation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 118 * IMPORTANT: If any wires are worn through enough to short out against each other, if strands of wire are broken, or if an "open" wiring condition is found, refer to Section 8A of the applicable Service Manual for proper wiring repair. - Install wiring harness back into conduit. Before clipping retainer closed, pull the harness towards the center of the vehicle to remove any slack in the harness. This will keep the harness off the transaxle case and away from the transaxle controls. - Clip harness retainer into position. - Reinstall clutch cables and retainer. (Manual transaxle only). - Reinstall secondary ignition cables and bracket. Warranty and Labor Time Information: For taping and repositioning harness: Labor Code: T1789 Labor Time: 0.3 Hours For wiring repair, taping and repositioning of harness: Labor Code: T1789 Labor Time 0.4 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 91423A3C > Feb > 92 > Suspension (Front) - Squawking/Clunking Noise Stabilizer Bushing: All Technical Service Bulletins Suspension (Front) - Squawking/Clunking Noise REVISED Number: 91-423A-3C Section: 3C Date: FEB. 1992 Corporate Bulletin No.: 133304R ASE No.: A4 Subject: SQUAWK/CLUNK NOISE FROM FRONT SUSPENSION Model and Year: 1985-91 CAVALIER 1987-91 CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 92-423-3C, DATED, SEPTEMBER 1991. THE LABOR OPERATION NUMBER HAS BEEN REVISED. ALL COPIES OF 91-423-3C SHOULD BE DISCARDED. CONDITION: Some 1985-91 J/L cars might exhibit a condition of a "Squawk" OR "Clunk" noise from the front suspension or engine compartment area when driving over small bumps or entering parking lots (i.e. washboard road surfaces, railroad tracks). CAUSE: The condition may be caused by the rubber bushing material bleeding through the teflon/polyester sock and coming into contact with the stabilizer bar. CORRECTION: If this condition is encountered, replace both stabilizer bar bushings with newer designed bushings. The part numbers for the new bushings are listed below: STABILIZER BAR DIAMETER BUSHING PART NUMBER(S) 22 mm 22566673 24 mm 22566674 26 mm 22566675 28 mm 22566676 30 mm 10088389 Parts are currently available from GMSPO. WARRANTY INFORMATION: Labor Operation Number: E2180 Labor Time: See Current Labor Time Guide TROUBLE CODE: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 129 Ignition Control Module: Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 130 Ignition Control Module: Description and Operation Coil Assembly The DIS module monitors the crank sensor signals and based on these signals sends a reference signal to the ECM so that correct spark and fuel injector control can be maintained during all driving conditions. During cranking, the DIS module monitors the "sync pulse" to begin the ignition firing sequence, and below 400 rpm the module controls spark advance by triggering each of the three coils at a pre-determined interval based on engine speed only. Above 400 rpm, the ECM controls the spark timing through the module (EST), and compensates for all driving conditions. The DIS module must receive a "sync pulse" and then a crank signal in that order to enable the engine to start. The DIS module is not repairable. When a module is replaced, the remaining DIS module components must be transferred to the new module. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 131 Ignition Control Module: Service and Repair Coil Assembly Remove or Disconnect 1. Negative battery cable. 2. DIS assembly from engine. 3. Coils from assembly. 4. Module from assembly plate. Install or Connect 1. Module to assembly plate. (Carefully engage sensor to module terminals.) 2. Coils. 3. DIS assembly to engine. 4. Negative battery cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations Windshield Washer Control Module: Locations Behind LH Side Of I/P, Strapped To RH Side Of Steering Column Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations Lower Center Portion Of Tailgate Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations LH Front Of Dash. In LH Side Of Brake Fluid Reservoir Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch Brake Fluid Pressure Sensor/Switch: Description and Operation Brake Distribution Valve & Switch Fig. 16 Brake Distribution Switch. Normal Fig. 17 Brake Distribution Switch. Failed DESCRIPTION This switch assembly is used on some diagonally split brake systems and Corvette four wheel disc brake systems. It is connected to the outlet ports of the master cylinder and to the brake warning lamp and warns the driver if either the primary or secondary brake system has failed. OPERATION When hydraulic pressure is equal in both primary and secondary brake systems, the switch remains centered (figure 16). If pressure fails in one of the systems, the piston moves toward the inoperative side (figure 17). The shoulder of the piston contacts the switch terminal, providing a ground and lighting the warning lamp. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 149 Brake Fluid Pressure Sensor/Switch: Description and Operation Brake Warning Lamp Switches Fig. 4 Pressure Differential Valve & Brake Warning Lamp Switch Fig. 5 Pressure Differential Valve & Brake Warning Lamp Switch Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 150 Fig. 6 Pressure Differential Valve & Brake Warning Lamp Switch Fig. 7 Dual Master Cylinder With Built In Warning Lamp Switch There are four basic types of brake warning lamp switches as shown, Figs. 4 through 7. When a pressure differential occurs between the front and rear brake systems, the valves will shuttle toward the side with the low pressure. In the switch shown in Fig. 4, movement of the differential valve forces the switch plunger upward over the tapered shoulder of the valve to close the switch contacts and light the dual brake warning lamp, signaling a brake system failure. In Fig. 5, the valve assembly consists of two valves in a common bore that are spring loaded toward the centered position. The spring-loaded switch contact plunger rests on top of the valves in the centered position (right view). When a pressure differential occurs between the front and rear brake systems, the valves will shuttle toward the side with the low pressure. The spring-loaded switch plunger is ``triggered'' and the ground circuit for the warning lamp is completed, lighting the lamp (left view). In Fig. 6, as pressure falls in one system, the other system's normal pressure forces the piston to the inoperative side, contacting the switch terminal, causing the warning lamp on the instrument panel to glow. Fig. 7 shows the switch mounted directly in the master cylinder assembly. Whenever there is a specified differential pressure, the switch piston will activate the brake failure warning switch and cause the brake warning lamp to glow. Testing Warning Lamp Operation The warning lamp should illuminate when the ignition switch is in the start position, and turn off when the switch returns to run. If the brake lamp remains on after the ignition returns to run, check fluid level in master cylinder reservoir and inspect parking brake. If the warning lamp does not turn on during cranking, check for defective bulb or blown fuse. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 151 Brake Fluid Pressure Sensor/Switch: Description and Operation Combination Valve Fig. 8 Combination Valve The combination valve, Fig. 8 is a metering valve, failure warning switch, and a proportioner in one assembly and is used on disc brake applications. The metering valve delays front disc braking until the rear drum brake shoes contact the drum. The failure warning switch is actuated in event of front or rear brake system failure, in turn activating a dash warning lamp. The proportioner balances front to rear braking action during rapid deceleration. Fig. 9 Metering Valve. Initial Braking Fig. 10 Metering Valve. Continued Braking Metering Valve When the brakes are not applied, the metering valve permits the brake fluid to flow through the valve, thus allowing the fluid to expand and contract with temperature changes. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 152 When the brakes are initially applied, the metering valve stem moves to the left, preventing fluid to flow through the valve to the front disc brakes. This is accomplished by the smooth end of the metering valve stem contacting the metering valve seal lip at 4 to 30 psi, Fig. 9. The metering valve spring holds the retainer against the seal until a predetermined pressure is produced at the valve inlet port which overcomes the spring pressure and permits hydraulic pressure to actuate the front disc brakes, Fig. 10. The increased pressure into the valve is metered through the valve seal, to the front disc brakes, producing an increased force on the diaphragm. The diaphragm then pulls the pin, in turn pulling the retainer and reduces the spring pressure on the metering valve seal. Eventually, the pressure reaches a point at which the spring is pulled away by the diaphragm pin and retainer, leaving the metering valve unrestricted, permitting full pressure to pass through the metering valve. Fig. 11 Failure Warning Switch. Rear System Failure Failure Warning Switch If the rear brake system fails, the front system pressure forces the switch piston to the right, Fig. 11. The switch pin is then forced up into the switch, completing the electrical circuit and activates the dash warning lamp. When repairs are made and pressure returns to the system, the piston moves to the left, resetting the switch. The detent on the piston requires approximately 100 to 450 psi to permit full reset of the piston. In event of front brake system failure, the piston moves to the left and the same sequence of events is followed as for rear system failure except the piston resets to the right. Fluid Level Sensor This sensor mounted on the master cylinder will activate the Brake Warning lamp if a low brake fluid level is detected. The lamp will turn off once the fluid level is corrected. Fig. 12 Proportioner. Rapid Deceleration Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 153 Fig. 13 Proportioner. Normal Braking Fig. 14 Proportioners Installed In Master Cylinder Proportioning or Pressure Control Valve During rapid deceleration, a portion of vehicle weight is transferred to the front wheels. This resultant loss of weight at rear wheels must be compensated for to avoid early rear wheel skid. The proportioner or pressure control valve reduces rear brake system pressure, delaying rear wheel skid. When the proportioner or pressure control valve is incorporated in the combination valve assembly, pressure developed within the valve acts against the large end of the piston, overcoming the spring pressure, moving the piston left, Fig. 12. The piston then contacts the stem seat and restricts line pressure through the valve. During normal braking operation, the proportioner or pressure control valve is not functional. Brake fluid flows into the proportioner or pressure control valve between the piston center hole and the valve stem, through the stop plate and to the rear brakes. Spring pressure loads the piston during normal braking, causing it to rest against the stop plate, Fig. 13. On diagonally split brake systems, two proportioners or pressure control valves are used. One controls the left rear brake, the other the right rear brake. The proportioners or pressure control valves are installed in the master cylinder rear brake outlet ports, Fig. 14. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 154 Brake Fluid Pressure Sensor/Switch: Description and Operation Proportioning Valve Fig. 5 Gauge Hook-up For Testing Proportioning Valve (Typical) The proportioning valve (when used), Fig. 5, provides balanced braking action between front and rear brakes under a wide range of braking conditions. The valve regulates the hydraulic pressure applied to the rear wheel cylinders, thus limiting rear braking action when high pressures are required at the front brakes. In this manner, premature rear wheel skid is prevented. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations Parking Brake Release Switch: Locations In Console, At Base Of Parking Brake Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation Coolant Temperature Sensor (CTS) The engine coolant temperature sensor is a thermistor that is located in the engine coolant flow. When the coolant temperature is low, the sensor produces a high resistance. When the coolant temperature is high, the sensor produces a low resistance. The computer sends a 5.0 volt signal to the coolant temperature sensor through a resistor in the ECM and measures the voltage. The voltage will be high or low depending on coolant temperature. By varying the voltage, the computer will sense engine coolant temperature. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Locations Radiator Cooling Fan Temperature Sensor / Switch: Locations LH Front Of 2.2L LH Side Of Engine, Behind Coolant Outlet Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Combination Cruise/Stop Light Switch Brake Switch (Cruise Control): Description and Operation Combination Cruise/Stop Light Switch A separately mounted vacuum release valve is used with this combination switch. When the brake pedal is depressed, the switch resets the cruise function to a non-cruise condition and illuminates the brake lights. Two sets of electrical contacts are used in the switch: one to operate the stop lights, and the other to operate the cruise release function. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Combination Cruise/Stop Light Switch > Page 171 Brake Switch (Cruise Control): Description and Operation Combination Vacuum Release Valve/Converter Clutch Switch This combination valve and switch is used on vehicles equipped with a lock-up torque converter. The vacuum release valve portion operates identically to the release valve previously described. At the same time, the converter clutch switch contacts open and the locking clutch mechanism in the transmission is disengaged. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 172 Brake Switch (Cruise Control): Testing and Inspection An inoperative valve must be replaced. Ensure vacuum hose to switch is firmly connected and that it is not cracked or deteriorated. Vacuum source and hoses should be checked for improper routing, leaks, kinks or restrictions. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Description and Operation Clutch Switch: Description and Operation The clutch switch is used on vehicles equipped with manual transmission. When the clutch pedal is depressed, the cruise function is disconnected and will remain so after the pedal is released. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High Oil Pressure Sender: Customer Interest Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High > Page 185 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High Oil Pressure Sender: All Technical Service Bulletins Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High > Page 191 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Page 192 Oil Pressure Sender: Locations Rear Of Engine RH rear of engine, below intake manifold Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations Rear Of Engine RH rear of engine, below intake manifold Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 196 Oil Pressure Switch (For Fuel Pump): Description and Operation Wiring Diagram For Fuel Pump Relay As a back-up system to the fuel pump relay, the fuel pump can also be turned ON by the oil pressure switch. The oil pressure switch is a normally open switch which closes when oil pressure reaches about 28.0 kPa (4.0 psi). If the fuel pump relay fails, the oil pressure switch will power the fuel pump. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 197 Oil Pressure Switch (For Fuel Pump): Testing and Inspection Wiring Diagram For Fuel Pump Relay The oil pressure switch is mounted on the engine. This switch operates as a parallel power supply with the fuel pump relay to supply battery voltage to the fuel pump. Voltage is supplied to the fuel pump after approximately 28 kPa (4 PSI) oil pressure is reached. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 198 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch Located On RH Side Of Engine. Oil sender is located on right hand side of engine, under the DIS coils, under the intake manifold. Remove oil sender by using correct tool on the base of the sending unit. Do not use the body of the oil sender for installation/removal. Use appropriate sealer on threads. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Description and Operation Air Conditioning Switch: Description and Operation A/C "ON" Signal This signal indicates that the A/C control switch is turned "ON" and the pressure switch is closed. The computer uses this signal to adjust the idle speed, and on some models engages the A/C compressor clutch. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > A/C High Pressure Cut-Out Switch Refrigerant Pressure Sensor / Switch: Locations A/C High Pressure Cut-Out Switch RH Front Of Engine RH front of engine, below generator Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > A/C High Pressure Cut-Out Switch > Page 207 Refrigerant Pressure Sensor / Switch: Locations A/C Low Pressure Cut-Out Switch RH Front Of Engine RH front of engine, on LH end of A/C compressor Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 208 Refrigerant Pressure Sensor / Switch: Service and Repair 1. Discharge A/C system. 2. Remove retaining ring using suitable snap ring pliers, then the control valve or switch. 3. Remove and discard O-rings. 4. Coat replacement O-rings with clean refrigerant oil, then seat O-rings in proper grooves in housing. 5. Lubricate control valve or switch with clean refrigerant oil, then press into place. 6. Install retaining ring with high point of curved sides toward switch or valve housing, ensuring that ring is fully seated. 7. Evacuate and recharge system, then check for leaks. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Locations Refrigerant Temperature Sensor: Locations RH Front Of 3.1L RH Front Of Engine Compartment, On A/C Line Applicable to: 1L/V6-192 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Panel Dimmer Switch Dimmer Switch: Locations Panel Dimmer Switch Behind LH Side Of I/P LH side of I/P, near LH front speaker Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Panel Dimmer Switch > Page 219 Behind LH Side Of I/P Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 222 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 223 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 224 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 225 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 226 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 227 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 228 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 229 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 230 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 231 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 232 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 233 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 234 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 235 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 236 Dimmer Switch: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 237 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 238 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 239 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 240 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 241 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 242 Dimmer Switch: Electrical Diagrams Interior Lights Dimming Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 243 Interior Lights Dimming Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations In Respective Front Door Latch Assembly Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fuel Tank Unit And Lines (Typical) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 250 Fuel Pump/Fuel Gauge Sending Unit (typical) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 251 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit (typical) REMOVAL: 1. Before servicing the fuel pump the fuel system pressure must be relieved, see MAINTENANCE PROCEDURES. 2. Disconnect the negative battery cable. 3. Raise the car on a hoist. 4. Remove the fuel tank, 5. Remove the fuel tank sending unit and pump assembly by turning the cam lock ring counterclockwise. Lift assembly from the fuel tank. 6. Pull the fuel pump up into the attaching hose while pulling outward away from the bottom support. Take care to prevent damage to the rubber insulator and strainer during removal. After the pump assembly is clear of the bottom support, pull the pump assembly out of the rubber connector for removal. NOTE: Inspect the fuel pump attaching hose for any signs of deterioration. Also check the rubber sound insulator at the bottom of the pump. Replace damaged or deteriorated parts. INSTALLATION: 1. Push the fuel pump assembly into the attaching hose. 2. Position the fuel tank sending unit and pump assembly into the fuel tank. Use a new "O" ring seal. NOTE: Care should be taken not to fold over or twist the strainer when installing the sending unit as this will restrict the flow of fuel. Also, verify that the strainer does not block the full travel of the float arm. 3. Install cam lock over the assembly and lock by turning clockwise. 4. Reinstall fuel tank. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 252 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations On Top LH Side Of Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission Backup Lamp Switch: Service and Repair Automatic Transmission On vehicles equipped with automatic transmission, the neutral start and back-up light switches are combined into one unit and must be replaced as an assembly. 1. Disconnect battery ground cable. 2. On 1989 Skyhawk and 1989-90 Cavalier models, remove console assembly as follows: a. Apply parking brake and block wheels, then place gear shift lever in Neutral position. b. Remove front ashtray, then remove two console attaching screws through ashtray opening. c. Carefully pry button from center of shift lever knob, then remove snap ring retaining knob. d. Pull front of console trim cover upward, then lift trim cover from console and disconnect wire connector. e. Remove three screws attaching front of console to mounting bracket. f. Remove rear ashtray, then remove screw attaching console to rear support. g. Remove console assembly. On models equipped with arm rest, it may be necessary to remove arm rest assembly to provide clearance for console removal. 3. On Sunbird models, remove console assembly as follows: a. Position gear selector in Neutral and block wheels. Do not apply parking brake. b. Carefully pry accessory trim panel, right and left side panels outward from console assembly. c. Remove console to instrument panel attaching nuts. d. Remove console assembly to console upper bracket attaching screws. e. Disconnect tape and disc player electrical connectors, then remove upper console bracket. f. Remove shift lever knob to shift lever attaching setscrew or retainer, then pry shift lever trim plate upward. g. Remove rear ashtray to console rear trim plate attaching screws, then remove rear ashtray. h. Remove console rear trim plate to console rear bracket attaching screw. i. On models equipped with armrest, remove armrest inner compartment attaching screw, then remove armrest to console rear bracket attaching screws, then remove armrest assembly. j. On all models, remove parking brake assembly and console from console mounting brackets. 4. On 1991-92 Cavalier models, remove console assembly as follows: a. Carefully pry accessory trim panel outward. b. Open ashtray, then remove attaching screw. c. Remove shift lever knob to shift lever attaching retainer. d. Disconnect cigar lighter electrical connector, then remove shifter trim plate. e. Remove upper and lower A/C-Heater control attaching screws. f. Disconnect radio electrical connector and antenna lead, then remove radio assembly. g. Disconnect A/C-Heater control electrical connectors and vacuum harness, then remove bowden cable to A/C-Heater control attaching screw, then remove A/C-Heater control assembly. h. Remove console to instrument panel attaching screws. i. Remove console rear storage compartment attaching screws. j. Disconnect remaining console electrical connectors, then remove console assembly. k. Remove console extension to front console bracket and shift control bracket attaching screws, then remove console extension. 5. On all models, disconnect wire connector from Neutral Safety/Back-up light switch. 6. Remove screws attaching switch to shifter lever, then remove switch. 7. If the same switch is to be reinstalled, proceed as follows: a. Place shift lever in Neutral position. b. Position switch to shift lever and loosely install attaching screws. c. Rotate switch on shifter to align adjustment hole with carrier tang, then insert a 3/32 inch maximum diameter pin into hole to a depth of 9/64 inch. d. On models, except 1991-92 Cavalier, torque switch attaching screws to 22 ft. lbs., then remove gauge pin. On 1991-92 Cavalier models, torque switch attaching screw to 18 ft. lbs., then remove gauge pin. 8. If a new replacement switch is to be installed, proceed as follows: a. Position shift lever in the Neutral position. b. Align shift shaft flats to switch flats. c. On models except 1991-92 Cavalier, torque switch attaching bolts to 22 ft. lbs. On 1991-92 Cavalier models, torque switch attaching bolts to 18 ft. lbs. If mounting bolts do not align with mounting holes ensure shift shaft is in Neutral position. Do not rotate switch. d. Ensure engine will only start in Park or Neutral. e. If engine will start in any other position place shift lever in Neutral position. f. Position switch to shift lever and loosen switch attaching screws. g. Rotate switch on shifter assembly to align service adjustment hole with carrier tang hole, then insert a 3/32 inch maximum diameter gauge pin into hole to a depth of 5/8 inch. h. Torque switch attaching screws to previous specified torque, then remove gauge pin. 9. Install console and connect battery ground cable. 10. Check to ensure that vehicle will not start in any shift lever position except Neutral and Park. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission > Page 259 Backup Lamp Switch: Service and Repair Manual Transmission 1. Disconnect battery ground cable. 2. Disconnect back-up lamp switch electrical connector. 3. Remove back-up lamp switch from top of transaxle case. 4. Reverse procedure to install. Prior to installation, apply sealant 1052080 or equivalent to switch threads. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Below LH Side Of I/P. Behind I/P, On Brake Pedal Support Applicable to: Cavalier w/Automatic Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 263 Brake Light Switch: Adjustments Insert stop lamp switch in retainer until switch body seats on retainer. Pull brake pedal upward against internal pedal stop. Switch will be moved in retainer providing proper adjustment. Proper switch adjustment is achieved when no audible clicks are heard when the pedal is pulled upward and the brake lights do not remain on without brake application. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 264 Brake Light Switch: Service and Repair 1. Disconnect battery ground cable. 2. On 1991-92 models, remove drivers' side hash panel. 3. On all models, disconnect switch electrical connector. 4. Remove switch from brake pedal support bracket. 5. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations In Respective Front Door Latch Assembly Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 272 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 273 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 274 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 275 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 276 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 277 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 278 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 279 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 280 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 281 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 282 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 283 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 284 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 285 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 286 Headlamp Switch: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 287 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 288 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 289 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 290 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 291 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 292 Headlamp Switch: Electrical Diagrams Light Switch Details Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 293 Light Switch Details Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 294 Light Switch Details Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > Turn Signal Switch - Correct Cancellation After R&R; Turn Signal Switch: Technical Service Bulletins Turn Signal Switch - Correct Cancellation After R&R; Number: 93-181-3F Section: 3F Date: MAY 1993 Corporate Bulletin No.: 333204 ASE No.: A4 Subject: INFORMATIONAL PROCEDURE TO INSURE CORRECT TURN SIGNAL SWITCH CANCELLATION WHEN INSTALLING NEW SWITCH Model and Year: 1991-93 CAVALIER SERVICE UPDATE When replacing an inoperative turn signal switch, pay attention to the tightening sequence of the mounting bolts. It is important to torque the upper bolt first, and secondly the lower bolt. Both bolts should be tightened to 3-5 N-m (27-44 lbs. in.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation Coolant Temperature Sensor (CTS) The engine coolant temperature sensor is a thermistor that is located in the engine coolant flow. When the coolant temperature is low, the sensor produces a high resistance. When the coolant temperature is high, the sensor produces a low resistance. The computer sends a 5.0 volt signal to the coolant temperature sensor through a resistor in the ECM and measures the voltage. The voltage will be high or low depending on coolant temperature. By varying the voltage, the computer will sense engine coolant temperature. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 308 Crankshaft Position Sensor: Mechanical Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 309 Rear Of Engine Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 310 Crankshaft Position Sensor: Description and Operation Typical DIS Crankshaft Sensor This crankshaft sensor is mounted remotely on the bottom side of the ignition module. This sensor protrudes into the block, within approximately 0.050" of the engine crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots cast into it, six of which are evenly spaced 60° apart. A seventh slot is spaced 10° from one of the other slots and serves to generate a "sync pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the crank pulses, the DIS module sends reference signals to the ECM which are used to indicate crankshaft position and engine speed. The ignition module will continue to send these reference pulses to the ECM at a rate of one for each 180° or crankshaft rotation. The ECM will activate the fuel injector based on the recognition of every other reference pulse beginning at a crankshaft position of 120° after top dead center. By comparing the time between pulses, the DIS module can recognize the pulse representing the seventh slot or "sync pulse," which starts the calculation of the ignition coil sequence. The second crank pulse following the "sync pulse" signals the "DIS" module to fire the #2/3 ignition coil and the fifth crank pulse signals the module to fire the #1/4 ignition coil. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Torque Valve Torque Valve Induction Air Sensor 44 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 314 Intake Air Temperature Sensor: Locations Top Rear Of 2.2L Top LH Rear Of Engine, In Air Cleaner Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 315 Intake Air Temperature Sensor: Description and Operation IAT Sensor (Typical) The Intake Air Temperature (IAT) sensor uses a thermistor to control the signal voltage to the ECM. The variable resistor changes its resistance based on temperature. Low intake air temperature produces high resistance, 100,000 ohms at -40°C (-40°F), while a high temperature causes low resistance, 70 ohms at 130°C (266°F). The ECM supplies a 5.0 volt signal to the IAT sensor through a resistor in the ECM and monitors the voltage change. By monitoring the voltage, the ECM calculates the air temperature and uses this data to assist in determining fuel delivery and spark advance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Voltage 3.6 to 5.2 V at 1000 to 2000 ft Note: Note: Apply 10 in. Hg to MAP SENSOR at given altitude and watch voltage. It should drop 1.0 to 1.5 Volts from Voltage Specification given. 3.5 to 5.1 V at 2000 to 3000 ft 3.3 to 5.0 V at 3000 to 4000 ft 3.2 to 4.8 V at 4000 to 5000 ft 3.0 to 4.6 V at 5000 to 6000 ft 2.9 to 4.5 V at 6000 to 7000 ft 2.8 to 4.3 V at 7000 to 8000 ft 2.6 to 4.2 V at 8000 to 9000 ft 2.5 to 4.0 V at 9000 to 10000 ft Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 322 Manifold Pressure/Vacuum Sensor: Locations Engine Component Locations. RH Front Of Dash, LH Side Of Blower Motor Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 323 Manifold Pressure/Vacuum Sensor: Description and Operation Map Sensor The Manifold Absolute Pressure (MAP) sensor measures changes in the intake manifold pressure resulting from engine load and speed changes. The computer sends a 5.0 volt reference signal to the MAP sensor. As pressure changes in the intake manifold occur, the electrical resistance of the MAP sensor also changes. By monitoring the sensor output voltage, the computer can determine the manifold absolute pressure. The higher the MAP voltage output the lower the engine vacuum, which requires more fuel. The lower the MAP voltage output the higher the engine vacuum, which requires less fuel. Under certain conditions, the MAP sensor is also used to measure barometric pressure. This allows the computer to automatically adjust for different altitudes. The computer uses the MAP sensor to control fuel delivery and ignition timing. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 324 Manifold Pressure/Vacuum Sensor: Testing and Inspection Chart C-1D Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 325 Wiring Diagram For MAP Sensor CIRCUIT DESCRIPTION: The Manifold Absolute Pressure (MAP) sensor responds to changes in manifold pressure (vacuum). The ECM sends a five volt reference to the MAP sensor. As manifold pressure changes, the output voltage of the sensor also changes. By monitoring the sensor output voltage, the ECM knows the manifold pressure. A lower pressure output voltage will be approximately 1.0-2.0 volts at idle. Higher pressure output voltage will be approximately 4.0-4.8 volts at Wide Open Throttle (WOT). The MAP sensor is also used, under certain conditions, to measure barometric pressure. This allows the ECM to make engine adjustments for different altitudes. The ECM uses the MAP sensor information to control fuel delivery and ignition timing. TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. 1. When comparing "Scan" readings to a known good vehicle, it is important to compare vehicles that use a MAP sensor having the same color insert or having the same "Hot Stamped" number. 2. Applying 34 kPa (10" Hg.) of vacuum to the MAP sensor should cause the voltage to change. The voltage value should be greater than 1.5 volts. Upon applying vacuum to the sensor, the change in voltage should be instantaneous. A slow voltage change indicates a faulty sensor. 3. Check vacuum hose to sensor for a leak or a restriction. Be sure that no other vacuum devices are connected to the MAP sensor hose. 4. Disconnect sensor from the bracket and twist sensor by hand to check for an intermittent connection. Output changes greater than 0.1 volt indicate a bad connector or connection. If OK, replace the sensor. NOTE: Make sure electrical connector remains securely fastened, and the same diagnostic test equipment is used on all measurements. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensors - Silica Contamination Oxygen Sensor: Technical Service Bulletins Oxygen Sensors - Silica Contamination Model Year: 1981 Bulletin No: 81-I-37 File In Group: 60 Number: 11 Date: Feb. 81 Subject: Silica Contamination of Oxygen Sensors and Gelation of Oil. Models Affected: All Oxygen sensor performance can deteriorate if certain RTV silicone gasket materials are used. Other RTV's when used with certain oils, may cause gelation of the oil. The degree of performance severity depends on the type of RTV and application of the engine involved. Therefore, when repairing engines where this item is involved, it is important to use either cork composition gaskets or RTV silicone gasket material approved for such use. GMS (General Motors Sealant) or equivalent material can be used. GMS is available through GMPD with the following part numbers: 1052366 3 oz. 1052434 10.14 oz. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 330 Oxygen Sensor: Specifications MINIMUM IDLE SPEED Transmission Gear Idle Speed IAC Counts Open/Closed Loop (2) Auto. D 600 +/-50 (1) CL Man. N 600 +/-50 (1) CL (1) No IAC counts are provided for this vehicle. (2) Let engine idle until proper fuel control status is reached (open/closed loop). TORQUE VALUES EGR valve bolts.................................................................................................................................... .............................................11-18 lb.ft. (15-25 N-m) Oxygen sensor..................................................................................................................................... ..........................................................30 lb.ft. (41 N-m) Throttle Body attaching bolts................................................................................................................ ........................................................18 lb.ft. (25 N-m) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 331 Oxygen Sensor: Locations Engine Component Locations. Front Of Engine, In Exhaust Manifold Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 332 LH Front Of 2.2L Front Of Engine, In Exhaust Manifold Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 333 Oxygen Sensor: Description and Operation Oxygen Sensor The oxygen sensor is located in the exhaust system. The sensor monitors atmospheric air versus exhaust gas oxygen content to produce a voltage output. This voltage ranges from approximately 0.1 volt (high oxygen - lean mixture) to 0.9 volt (low oxygen - rich mixture). By monitoring the oxygen sensor output voltage, the computer can determine the amount of oxygen in the exhaust gas and adjust the air/fuel mixture accordingly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 334 Oxygen Sensor: Service and Repair The oxygen sensor has a permanently attached wire and connector. This should not be removed, since the removal will affect proper operation of the oxygen sensor. 1. Disconnect electrical connector from oxygen sensor. 2. Using a suitable oxygen sensor wrench, carefully remove the sensor from exhaust manifold or pipe. The oxygen sensor may be difficult to remove when engine temperature is below 120°F. Use CAUTION, since excessive force may damage threads in exhaust manifold or pipe. 3. If a new sensor is being used, install the new sensor into the manifold or pipe. 4. If an old sensor is being reused, coat threads with anti-seize compound, then install the sensor into the manifold or pipe. 5. Torque the oxygen sensor to specifications, then reconnect the electrical connector. See MECHANICAL SPECIFICATIONS for sensor torque specifications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations RH Rear Of Engine Compartment. LH Front Of Dash, Below Brake Booster Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 338 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch The Power Steering Pressure Switch (PSPS) opens during high pressure power steering situations. When the power steering switch is open, power to the A/C relay is shut off, resulting in air conditioning compressor clutch disengagement. A signal is also sent to the ECM. The ECM uses this signal for idle speed control. A Scan tool should read "off" normally, and "on" with high pressure. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 343 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor 18 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 344 Throttle Position Sensor: Locations Top Rear Of 2.2L Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 2L/4-134 Engine. 1991 Cavalier Engine Component Locations. Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 345 Throttle Position Sensor: Description and Operation Typical Throttle Position Sensor (TPS) Wiring Throttle Position Sensor PURPOSE The function of the Throttle Position Sensor (TPS) is to sense the current throttle valve position and relay that information to the ECM. Throttle position information allows the ECM to generate the required injector control signals (base pulse). OPERATION If the TPS senses a opening throttle, a voltage signal indicating this condition is sent to the ECM. The ECM then increases the injector pulse width, permitting increased fuel flow. As the throttle valve rotates in response to movement of the accelerator pedal, the throttle shaft transfers this rotation to the TPS. A potentiometer (variable resistor) within the TPS assembly changes its resistance (and voltage drop) in proportion to throttle movement. By applying a reference voltage (5.0 volts) to the TPS input, a varying voltage (reflecting throttle position) is available at the TPS output. For example, approximately 2.5 volts results from a 50% throttle valve opening (depending on TPS calibration). The voltage output from the TPS assembly is routed to the ECM for use in determining throttle position. If the TPS is held in a wide open throttle (WOT) position during engine start, the ECM will interpret this as a clear flood mode. The ECM will then pulse the injectors at a ratio of 20 to 1 in order to clear a flooded condition. The ECM will hold this injector rate as long as the throttle stays wide open, and the engine speed is below 600 rpm. LOCATION The Throttle Position Sensor (TPS), is mounted on the side of the throttle body opposite the throttle lever assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 346 Throttle Position Sensor: Adjustments TPS Adjustment Check The Throttle Position Sensor (TPS) is not adjustable. The normal closed throttle position voltage is below 1.33 volts, and normal wide open throttle position voltage is approximately 5.0 volts. If these limits are not in specification, check for freedom of throttle movement, and accelerator pedal interference from carpets and other obstructions. If the problem is not corrected, replace the TPS. The ECM has the ability to self zero the TPS voltage if it is below approximately 1.33 volts. A TPS voltage that does not fall within 0.33 volts and 1.33 volts should be replaced after checking connections. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 347 Throttle Position Sensor: Service and Repair Model 700 TBI - Exploded View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 348 Throttle Position Sensor REMOVAL: 1. Disconnect the electrical connector. 2. Remove TPS attaching screws. 3. Remove the TPS. CAUTION: The TPS is an electrical component and must not be soaked in any liquid cleaner or solvent, as damage may result. INSTALLATION: 1. With the throttle valve in the closed position, install the TPS on the throttle shaft. Rotate counter clockwise to align mounting holes. 2. Install the TPS attaching screws, finger tighten only. 3. Tighten attaching screws to 2.0 N-m (18 lb. in.) 4. Check TPS voltage: a. Connect a scan tool to the ALDL connector. b. Turn the ignition switch ON. c. Select TPS voltage display on the scan tool, and check voltage. The TPS voltage should be less than 1.25 volts. If the reading is higher than 1.25 volts, check for binding throttle valve or throttle cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations Transmission Position Switch/Sensor: Locations Rear Of 3.1L Rear Of Engine, Top LH Side Of Transaxle Applicable to: 1L/V6-192 Engine. Cavalier w/Automatic Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 352 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch & Connector The PARK/NEUTRAL switch indicates to the computer when the transmission is in park or neutral. This information is used by the computer for ignition timing, Idle Air Control (IAC), and Transmission Torque Converter Clutch (TCC) operation. DO NOT drive the vehicle with the PARK/NEUTRAL switch disconnected, since idle quality may be affected. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 353 Transmission Position Switch/Sensor: Testing and Inspection Chart C-1A Wiring Diagram For P/N Switch CIRCUIT DESCRIPTION: The PARK/NEUTRAL switch contacts are closed to ground in park or neutral and open in drive ranges. The ECM supplies ignition voltage through a current limiting resistor to circuit 434, and senses a closed switch when the voltage on circuit 434 drops to less than one volt. The ECM uses the P/N signal as one of the inputs to control idle air and vehicle speed sensor diagnostics. TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 354 1. Checks for a closed switch to ground in the PARK position. Different makes of "Scan" tools will read PARK/NEUTRAL differently. Refer to operators manual for type of display used for a specific tool. 2. Checks for an open switch in drive range. 3. Be sure the "Scan" tool indicates drive even while wiggling the shifter to test for an intermittent or misadjusted switch in drive. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 355 Transmission Position Switch/Sensor: Adjustments 1. Place transaxle shift lever in NEUTRAL. 2. Loosen switch attaching screws. 3. Rotate switch on shaft assembly to align service adjustment hole with carrier tang hole. a. Insert 2.34 mm (3/32 inch) maximum diameter gauge pin to a depth of 15.0 mm (5/8 inch). 4. Tighten attaching screws. See SPECIFICATIONS/MECHANICAL for torque values. 5. Remove the gauge pin. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 356 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Start and Backup Lamp Switch 1. Remove negative battery cable, shift linkage, electrical connector, mounting bolts, and switch assembly. 2. Replacement using old or new switch. a. Place shift shaft in NEUTRAL. b. Align flats of shift shaft with switch. c. Old Switch only - Install mounting bolts-to-case, loosely. Insert gauge pin in service adjustment hole, and rotate switch until pin drops into a depth of 9.0 mm (9/64") and tighten bolts (see SPECIFICATIONS/MECHANICAL for torque values). d. New Switch only - Install mounting bolts and tighten. If bolt holes do not align with mounting boss on transaxle, verify that the shift shaft is in NEUTRAL; DO NOT rotate the switch. The switch is pinned in the NEUTRAL position. NOTE: If the switch has been rotated and the pin is broken, the switch can be adjusted using the old switch procedure and ADJUSTMENT PROCEDURES. 3. See ADJUSTMENT PROCEDURES for PARK/NEUTRAL switch adjustment. 4. After the switch is installed, verify that the engine will start only in PARK (A/T) or NEUTRAL (M/T). If the engine starts in any other position, readjust the switch using old switch procedure and ADJUSTMENT PROCEDURES. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Engine Component Locations. Top RH Rear Of Transaxle Applicable to: 1991 Cavalier w/2.2L/4-134 Rear Of 2.2 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 360 Top RH Rear Of Transaxle Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 361 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor The Vehicle Speed Sensor (VSS) is made up of a coil, which is mounted on the transmission, and a tooth rotor which is mounted to the output shaft in the transmission. As each rotor tooth nears the coil, the coil produces an Alternating Current (AC) voltage pulse. As the vehicle speed increases, the number of AC voltage pulses increase. The Digital Ratio Adapter Controller (DRAC) processes input from the VSS sensor and output signals from the speedometer, computer, and cruise control module. The DRAC takes the voltage pulses from the VSS sensor and uses them to open and close four solid state output switches to ground at a rate proportional to vehicle speed. The DRAC is matched to the vehicle based on final drive ratio and tire size. It is important to make sure the correct DRAC module is replaced on the vehicle if replacement is necessary. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations Rear Of Engine RH rear of engine, below intake manifold Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 366 Oil Pressure Switch (For Fuel Pump): Description and Operation Wiring Diagram For Fuel Pump Relay As a back-up system to the fuel pump relay, the fuel pump can also be turned ON by the oil pressure switch. The oil pressure switch is a normally open switch which closes when oil pressure reaches about 28.0 kPa (4.0 psi). If the fuel pump relay fails, the oil pressure switch will power the fuel pump. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 367 Oil Pressure Switch (For Fuel Pump): Testing and Inspection Wiring Diagram For Fuel Pump Relay The oil pressure switch is mounted on the engine. This switch operates as a parallel power supply with the fuel pump relay to supply battery voltage to the fuel pump. Voltage is supplied to the fuel pump after approximately 28 kPa (4 PSI) oil pressure is reached. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 368 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch Located On RH Side Of Engine. Oil sender is located on right hand side of engine, under the DIS coils, under the intake manifold. Remove oil sender by using correct tool on the base of the sending unit. Do not use the body of the oil sender for installation/removal. Use appropriate sealer on threads. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 373 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor 18 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 374 Throttle Position Sensor: Locations Top Rear Of 2.2L Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 2L/4-134 Engine. 1991 Cavalier Engine Component Locations. Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 375 Throttle Position Sensor: Description and Operation Typical Throttle Position Sensor (TPS) Wiring Throttle Position Sensor PURPOSE The function of the Throttle Position Sensor (TPS) is to sense the current throttle valve position and relay that information to the ECM. Throttle position information allows the ECM to generate the required injector control signals (base pulse). OPERATION If the TPS senses a opening throttle, a voltage signal indicating this condition is sent to the ECM. The ECM then increases the injector pulse width, permitting increased fuel flow. As the throttle valve rotates in response to movement of the accelerator pedal, the throttle shaft transfers this rotation to the TPS. A potentiometer (variable resistor) within the TPS assembly changes its resistance (and voltage drop) in proportion to throttle movement. By applying a reference voltage (5.0 volts) to the TPS input, a varying voltage (reflecting throttle position) is available at the TPS output. For example, approximately 2.5 volts results from a 50% throttle valve opening (depending on TPS calibration). The voltage output from the TPS assembly is routed to the ECM for use in determining throttle position. If the TPS is held in a wide open throttle (WOT) position during engine start, the ECM will interpret this as a clear flood mode. The ECM will then pulse the injectors at a ratio of 20 to 1 in order to clear a flooded condition. The ECM will hold this injector rate as long as the throttle stays wide open, and the engine speed is below 600 rpm. LOCATION The Throttle Position Sensor (TPS), is mounted on the side of the throttle body opposite the throttle lever assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 376 Throttle Position Sensor: Adjustments TPS Adjustment Check The Throttle Position Sensor (TPS) is not adjustable. The normal closed throttle position voltage is below 1.33 volts, and normal wide open throttle position voltage is approximately 5.0 volts. If these limits are not in specification, check for freedom of throttle movement, and accelerator pedal interference from carpets and other obstructions. If the problem is not corrected, replace the TPS. The ECM has the ability to self zero the TPS voltage if it is below approximately 1.33 volts. A TPS voltage that does not fall within 0.33 volts and 1.33 volts should be replaced after checking connections. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 377 Throttle Position Sensor: Service and Repair Model 700 TBI - Exploded View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 378 Throttle Position Sensor REMOVAL: 1. Disconnect the electrical connector. 2. Remove TPS attaching screws. 3. Remove the TPS. CAUTION: The TPS is an electrical component and must not be soaked in any liquid cleaner or solvent, as damage may result. INSTALLATION: 1. With the throttle valve in the closed position, install the TPS on the throttle shaft. Rotate counter clockwise to align mounting holes. 2. Install the TPS attaching screws, finger tighten only. 3. Tighten attaching screws to 2.0 N-m (18 lb. in.) 4. Check TPS voltage: a. Connect a scan tool to the ALDL connector. b. Turn the ignition switch ON. c. Select TPS voltage display on the scan tool, and check voltage. The TPS voltage should be less than 1.25 volts. If the reading is higher than 1.25 volts, check for binding throttle valve or throttle cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 384 Crankshaft Position Sensor: Mechanical Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 385 Rear Of Engine Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 386 Crankshaft Position Sensor: Description and Operation Typical DIS Crankshaft Sensor This crankshaft sensor is mounted remotely on the bottom side of the ignition module. This sensor protrudes into the block, within approximately 0.050" of the engine crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots cast into it, six of which are evenly spaced 60° apart. A seventh slot is spaced 10° from one of the other slots and serves to generate a "sync pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the crank pulses, the DIS module sends reference signals to the ECM which are used to indicate crankshaft position and engine speed. The ignition module will continue to send these reference pulses to the ECM at a rate of one for each 180° or crankshaft rotation. The ECM will activate the fuel injector based on the recognition of every other reference pulse beginning at a crankshaft position of 120° after top dead center. By comparing the time between pulses, the DIS module can recognize the pulse representing the seventh slot or "sync pulse," which starts the calculation of the ignition coil sequence. The second crank pulse following the "sync pulse" signals the "DIS" module to fire the #2/3 ignition coil and the fifth crank pulse signals the module to fire the #1/4 ignition coil. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking Ignition Switch Lock Cylinder: Customer Interest Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 396 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 397 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 398 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 399 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 400 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 401 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 931943F > May > 93 > Ignition Lock Cylinder - Replacement Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Replacement Number: 93-194-3F Section: 3F Date: MAY 1993 Corporate Bulletin No.: 333207 ASE No.: A4 Subject: IGNITION LOCK CYLINDER REPLACEMENT Model and Year: 1991-93 CAVALIER SERVICE UPDATE When drilling out the ignition lock cylinder housing assembly shear bolts, care must be taken to remove the steering column from the car. Both the wiper switch and the turn signal switch must be removed before drilling the bolts out. There is a concern that metal shavings from the drilling of ignition lock cylinder shear bolts may enter the switches and cause the switch to become inoperative. The revised procedure below should be used. REMOVE 1. Steering wheel and covers (see Section 3F). 2. Steering column from vehicle (see Section 3F). 3. Turn signal switch from steering column (see Section 3F). 4. Wash/wipe switch from steering column (see Section 3F). IMPORTANT: Both the turn signal switch and wash/wipe switch have to be removed to prevent any metal shavings from entering the electrical components. 5. Lock cylinder housing assembly as follows: Put key in run position. - Drill off heads of two shear bolts using a 6.5 mm (1/4") drill bit. - Remove lock cylinder housing assembly. - Remove threaded ends of shear bolts from lock cylinder housing assembly with locking type pliers. - Clean all metal shavings from all parts after drilling. INSTALL 1. Lock cylinder housing assembly with two shear bolts. Key in run position. 2. Tighten two shear bolts until bolt head separates from bolt body approximately 11.0 N-m (97 lbs.in.) 3. Wash/wipe switch onto steering column (see Section 3F). 4. Turn signal switch onto steering column (see Section 3F). 5. Steering column into vehicle (see Section 3F). 6. Steering wheel and covers (see Section 3F). NOTE: Because the correct procedure must be followed when replacing ignition lock cylinders, Warranty will not be paid on turn signal or wiper/wash switches for 30 days after an ignition lock cylinder replacement. Use current labor time. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 411 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 412 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 413 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 414 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 415 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 416 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 91451A8C > Mar > 92 > Oil Pressure Gauge Flutters/Reads High Oil Pressure Gauge: All Technical Service Bulletins Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 91451A8C > Mar > 92 > Oil Pressure Gauge Flutters/Reads High > Page 422 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 91451A8C > Mar > 92 > Oil Pressure Gauge Flutters/Reads High > Page 428 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Below RH Side Of Front Seat Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Start Switch <--> [Clutch Switch] > Component Information > Locations Clutch Start Switch: Locations Below LH Side Of I/P. Behind I/P, On Clutch Pedal Support Applicable to: 1991 Cavalier w/Manual Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Start Switch <--> [Clutch Switch] > Component Information > Locations > Page 444 Clutch Start Switch: Service and Repair 1. Disconnect clutch switch electrical connector. 2. Remove clutch bracket and switch attaching nuts, then remove switch. 3. Reverse procedure to install. Torque switch attaching nuts to 53 inch lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking Ignition Switch Lock Cylinder: Customer Interest Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 454 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 455 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 456 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 457 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 458 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 459 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 931943F > May > 93 > Ignition Lock Cylinder - Replacement Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Replacement Number: 93-194-3F Section: 3F Date: MAY 1993 Corporate Bulletin No.: 333207 ASE No.: A4 Subject: IGNITION LOCK CYLINDER REPLACEMENT Model and Year: 1991-93 CAVALIER SERVICE UPDATE When drilling out the ignition lock cylinder housing assembly shear bolts, care must be taken to remove the steering column from the car. Both the wiper switch and the turn signal switch must be removed before drilling the bolts out. There is a concern that metal shavings from the drilling of ignition lock cylinder shear bolts may enter the switches and cause the switch to become inoperative. The revised procedure below should be used. REMOVE 1. Steering wheel and covers (see Section 3F). 2. Steering column from vehicle (see Section 3F). 3. Turn signal switch from steering column (see Section 3F). 4. Wash/wipe switch from steering column (see Section 3F). IMPORTANT: Both the turn signal switch and wash/wipe switch have to be removed to prevent any metal shavings from entering the electrical components. 5. Lock cylinder housing assembly as follows: Put key in run position. - Drill off heads of two shear bolts using a 6.5 mm (1/4") drill bit. - Remove lock cylinder housing assembly. - Remove threaded ends of shear bolts from lock cylinder housing assembly with locking type pliers. - Clean all metal shavings from all parts after drilling. INSTALL 1. Lock cylinder housing assembly with two shear bolts. Key in run position. 2. Tighten two shear bolts until bolt head separates from bolt body approximately 11.0 N-m (97 lbs.in.) 3. Wash/wipe switch onto steering column (see Section 3F). 4. Turn signal switch onto steering column (see Section 3F). 5. Steering column into vehicle (see Section 3F). 6. Steering wheel and covers (see Section 3F). NOTE: Because the correct procedure must be followed when replacing ignition lock cylinders, Warranty will not be paid on turn signal or wiper/wash switches for 30 days after an ignition lock cylinder replacement. Use current labor time. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 469 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 470 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 471 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 472 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 473 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 474 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 914143E > Sep > 91 > Wheel Center Caps - Rattling Noise Wheel Cover: All Technical Service Bulletins Wheel Center Caps - Rattling Noise Number: 91-414-3E Section: 3E Date: SEPT. 1991 Corporate Bulletin No.: 133503 ASE No.: A2, A3, A4, A5, B1 Subject: RATTLE NOISE AS A RESULT OF LOOSE WHEEL CENTER CAPS Model and Year: 1991 CAVALIER WITH Z24 TRIM PACKAGE Condition: Some 1991 "J" cars with the Z24 trim package may exhibit a rattling noise due to the wheel center hub cap being loose. Cause: Loose fit between the wheel and wheel center cap caused by oversize diameter in wheel. Correction: Using channel-lock pliers, with a cloth on cap face to protect the disc from damage, rework the center cap wire retaining ring (as shown in the picture) in five places to provide a tight fit of the cap to the improperly machined wheels. Bend the wire ring toward the cap disc as shown to obtain a permanent set of approximately one (1) wire diameter. This condition effects all 1991 Chevrolet J cars with Z24 from 1991 start of production through VIN breakpoint M7194096. Labor Operation Number: T1761 Labor Time: 0.2 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 914143E > Sep > 91 > Wheel Center Caps - Rattling Noise > Page 480 Add Time: 0.2 (one or all) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 914143E > Sep > 91 > Wheel Center Caps - Rattling Noise > Page 486 Add Time: 0.2 (one or all) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Neutral Start Switch 20 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 492 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 493 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 494 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 495 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 496 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 497 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 498 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 499 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 500 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 501 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 502 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 503 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 504 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 505 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 506 Neutral Safety Switch: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 507 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 508 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 509 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 510 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 511 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 512 Neutral Safety Switch: Service and Repair Disable the Supplemental Inflatable Restraint (SIR) system as described in BODY ELECTRICAL SAFETY AND ENTERTAINMENT/PASSIVE RESTRAINTS, AIR BAG/MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING prior to working on or near the steering column. 1. Disconnect battery ground cable. 2. Disconnect shift cable from transaxle. 3. Disconnect electrical connector from switch. 4. Remove two switch mounting bolts and the switch. 5. Align flats on switch with flats on transaxle shaft and push switch over shaft and fully seat on transaxle. 6. Install and torque switch mounting bolts to 20 ft. lbs. If switch was rotated and the pin broken, the switch will be automatically reset to the neutral position as follows: a. Place transaxle shaft in neutral position. b. Install switch on transaxle as outlined previously and loosely install mounting bolts. c. Insert a 3/32 inch gauge pin into service adjustment hole of switch. d. Rotate switch until pin drops in detent. e. Torque mounting bolts to 20 ft. lbs. f. Rearm airbag system as described under BODY ELECTRICAL SAFETY AND ENTERTAINMENT/PASSIVE RESTRAINTS, AIR BAG/MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations RH Rear Of Engine Compartment. LH Front Of Dash, Below Brake Booster Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 518 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch The Power Steering Pressure Switch (PSPS) opens during high pressure power steering situations. When the power steering switch is open, power to the A/C relay is shut off, resulting in air conditioning compressor clutch disengagement. A signal is also sent to the ECM. The ECM uses this signal for idle speed control. A Scan tool should read "off" normally, and "on" with high pressure. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Specifications Fluid Pressure Sensor/Switch: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Pressure Switch ................................................................................................................................... ................................................................................. 8 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations Transmission Position Switch/Sensor: Locations Rear Of 3.1L Rear Of Engine, Top LH Side Of Transaxle Applicable to: 1L/V6-192 Engine. Cavalier w/Automatic Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 527 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch & Connector The PARK/NEUTRAL switch indicates to the computer when the transmission is in park or neutral. This information is used by the computer for ignition timing, Idle Air Control (IAC), and Transmission Torque Converter Clutch (TCC) operation. DO NOT drive the vehicle with the PARK/NEUTRAL switch disconnected, since idle quality may be affected. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 528 Transmission Position Switch/Sensor: Testing and Inspection Chart C-1A Wiring Diagram For P/N Switch CIRCUIT DESCRIPTION: The PARK/NEUTRAL switch contacts are closed to ground in park or neutral and open in drive ranges. The ECM supplies ignition voltage through a current limiting resistor to circuit 434, and senses a closed switch when the voltage on circuit 434 drops to less than one volt. The ECM uses the P/N signal as one of the inputs to control idle air and vehicle speed sensor diagnostics. TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 529 1. Checks for a closed switch to ground in the PARK position. Different makes of "Scan" tools will read PARK/NEUTRAL differently. Refer to operators manual for type of display used for a specific tool. 2. Checks for an open switch in drive range. 3. Be sure the "Scan" tool indicates drive even while wiggling the shifter to test for an intermittent or misadjusted switch in drive. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 530 Transmission Position Switch/Sensor: Adjustments 1. Place transaxle shift lever in NEUTRAL. 2. Loosen switch attaching screws. 3. Rotate switch on shaft assembly to align service adjustment hole with carrier tang hole. a. Insert 2.34 mm (3/32 inch) maximum diameter gauge pin to a depth of 15.0 mm (5/8 inch). 4. Tighten attaching screws. See SPECIFICATIONS/MECHANICAL for torque values. 5. Remove the gauge pin. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 531 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Start and Backup Lamp Switch 1. Remove negative battery cable, shift linkage, electrical connector, mounting bolts, and switch assembly. 2. Replacement using old or new switch. a. Place shift shaft in NEUTRAL. b. Align flats of shift shaft with switch. c. Old Switch only - Install mounting bolts-to-case, loosely. Insert gauge pin in service adjustment hole, and rotate switch until pin drops into a depth of 9.0 mm (9/64") and tighten bolts (see SPECIFICATIONS/MECHANICAL for torque values). d. New Switch only - Install mounting bolts and tighten. If bolt holes do not align with mounting boss on transaxle, verify that the shift shaft is in NEUTRAL; DO NOT rotate the switch. The switch is pinned in the NEUTRAL position. NOTE: If the switch has been rotated and the pin is broken, the switch can be adjusted using the old switch procedure and ADJUSTMENT PROCEDURES. 3. See ADJUSTMENT PROCEDURES for PARK/NEUTRAL switch adjustment. 4. After the switch is installed, verify that the engine will start only in PARK (A/T) or NEUTRAL (M/T). If the engine starts in any other position, readjust the switch using old switch procedure and ADJUSTMENT PROCEDURES. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Electronic Speed Sensor Retainer ...................................................................................................... ...................................................................... 7 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection Multi Function Lever Test Wiper Washer Switch Voltage Chart PROCEDURE Disconnect wiring harnesses from wiper motor and perform the following multi-function lever tests using a digital voltmeter with ignition switch on. All voltage readings taken with respect to vehicle ground. Probe terminals 1 through 4 with digital voltmeter and multi-function lever in various positions. If the Multi-Function Lever Test is not completed correctly, then the multi-Function lever is defective. However, it is possible that the wiring harness is defective and has an open or short. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Diagnostic Procedures Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 548 Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 549 condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 550 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 551 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 552 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 553 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications Alignment: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications > Page 559 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications > Page 560 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications > Page 561 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications > Page 562 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications > Page 563 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications > Page 564 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications > Page 565 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Diagnostic Procedures Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 570 Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 571 condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 572 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 573 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 574 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 575 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set Alignment: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 581 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 582 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 583 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 584 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 585 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 586 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 587 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 588 Alignment: By Symptom Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Diagnostic Procedures Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 589 Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 590 condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 591 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 592 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 593 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 594 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 595 Diagnostic Procedures Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 596 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 597 A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 598 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 599 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 600 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 601 Diagnostic Procedures Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 602 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 603 A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 604 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 605 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 606 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Alignment Specifications Front Wheel Alignment Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Alignment Specifications > Page 609 Rear Wheel Alignment Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Caster Adjustment Alignment: Service and Repair Front Caster Adjustment Caster is not adjustable. If caster angle is not within specifications, inspect for suspension support misalignment or front suspension damage. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Caster Adjustment > Page 612 Alignment: Service and Repair Front Camber Adjustment Fig. 1 Modifying Strut Bracket To Adjust Camber Toe setting is the only adjustment normally required. However, in special circumstances, such as damage due to road hazard or collision, camber may be adjusted by modifying the strut assembly. 1. Secure bottom of strut assembly in a suitable vise. 2. Enlarge bottom holes in outer flanges with a round file until holes in outer flanges match slots in inner flanges, Fig. 1. 3. Connect strut to steering knuckle and install bolts finger tight. 4. Grasp top of tire firmly, then move tire inboard or outboard until correct camber reading is obtained. Tighten retaining bolts enough to secure camber setting. 5. Remove wheel and tire and tighten strut to steering knuckle retaining bolts. On 1989-90 models, Torque strut to steering knuckle retaining bolts to 135 ft. lbs. On 1991-92 models, Torque strut to steering knuckle attaching bolt to 133 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Caster Adjustment > Page 613 Alignment: Service and Repair Front Toe Adjustment Fig. 2 Adjusting Toe Toe-out is controlled by tie rod position. Adjustment is made by loosening the clamp bolts at the steering knuckle end of the tie rods and rotating the rods to obtain proper toe setting, Fig. 2. After correct toe setting is obtained, tighten clamp bolts. Torque clamp bolts to 41 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure, Engine Running ......................................................................................................................................................... 62-90 kPa (9-13 P.S.I.) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 618 Fuel Pressure: Testing and Inspection Fuel System Schematic WARNING: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before connecting a fuel pressure test. Refer to Fuel Pressure Release Procedure. CAUTION To reduce the risk of fire and personal injury: 1. It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge. 2. A small amount of fuel may be released when disconnecting the fuel lines. Cover the fuel lines with a shop towel to catch any fuel leaking out. Place the towel in an approved container once the lines are disconnected. 3. DO NOT pinch or restrict nylon fuel lines to avoid severing. If nylon fuel lines become kinked, and cannot be straightened, they must be replaced. 4. Wear safety glasses at all times. FUEL PRESSURE TESTING 1. Loosen fuel filler cap to relieve fuel tank pressure. (DO NOT tighten at this time.) 2. Raise the vehicle to disconnect the fuel pump electrical connector, then lower the vehicle. 3. Start and run the engine until the residual fuel is consumed. Engage starter for three seconds to assure fuel pressure relief. 4. Disconnect the negative battery cable, and locate the fuel feed pressure line. 5. Connect fuel pressure gage, J-29658-B, in between the fuel feed line and the TBI unit. Use the appropriate adapters. 6. Raise the vehicle to connect the fuel pump electrical connector, then lower the vehicle. 7. Connect the negative battery terminal. 8. Perform fuel pressure checks. 9. Relieve the fuel system pressure. See steps 2 and 3. 10. Disconnect the negative battery terminal and remove fuel pressure gauge. 11. Tighten fuel filler cap and connect the negative battery terminal. 12. Cycle the ignition switch twice, waiting ten seconds between cycles. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Vin R, U, G, Minimum Idle Speed Vin R, U, G, Minimum Idle Speed Idle Speed Note: Let engine idle until proper fuel control status is closed loop. Manual Transmission Neutral 600 +/-50 rpm Automatic Transmission Drive 600 +/-50 rpm Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Idle Speed Idle Speed: Adjustments Idle Speed The throttle plate stop screw, or idle speed, is adjusted at the factory and covered with a plug to discourage unnecessary adjustment. But, if access to the throttle stop screw is necessary, the following procedure eliminates the removal of the Throttle Body unit from the intake manifold. If there is a complaint of high idle speed, vacuum leaks should be considered the most likely cause. The Electronic Control Module (ECM) controls the Idle Air Control (IAC) valve, and it is less likely that a stalling complaint would be due to incorrect idle speed. If either occurs see DIAGNOSIS BY SYMPTOM. If the Minimum Air Rate is suspected, be sure the Idle Air Control (IAC) valve is not "lost" (not actually at the location indicated by current IAC "counts"). The IAC valve could be "lost" if ECM power has been interrupted with the ignition "ON," or the IAC valve has been disconnected with the engine running since the last reset. CAUTION: To prevent engines from running at high speeds, be sure that the ignition is OFF and the vehicle is in PARK or NEUTRAL before connecting Idle Air Control (IAC) assembly, or installing/removing idle air passage plugs. Failure to do this may result in vehicle movement, which can result in personal and/or property damage. Stop Screw Plug Removal The Idle Speed may be checked using the following procedure: 1. Block drive wheels and apply parking brake. 2. Remove the air cleaner housing, and plug the Thermac vacuum port (if applicable). 3. Remove the idle stop screw plug with an awl. 4. Start the engine and allow it to reach operating temperature. 5. Connect a tachometer to the engine. 6. With Idle Air Control (IAC) valve connected, jump terminals A and B of the ALDL connector to ground the diagnostic terminal. See ON-BOARD DIAGNOSTIC CHECK for ALDL diagram. 7. Turn the ignition ON, but do not start the engine. Wait at least 45 seconds to allow the IAC pintle time to bottom in its seat. This closes the air passage in the TBI unit. 8. With the ignition ON, engine not running and diagnostic lead grounded, disconnect the IAC valve electrical connector. 9. Remove the ground from the diagnostic connector, and start the engine. Allow the engine speed to stabilize. 10. Adjust the idle stop screw. See MECHANICAL SPECIFICATIONS for idle speed specifications. 11. Turn OFF the ignition and reconnect the IAC electrical connector. 12. Reset the IAC valve by starting the engine and allowing it to run at 2000 rpm for ten seconds. Then turn OFF the ignition switch. 13. Cover the idle stop screw with silicone or similar sealant. 14. Remove the test instruments and reinstall the air cleaner housing. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Idle Speed > Page 624 Idle Speed: Adjustments Minimum Air Rate - Fuel Injection Only NOTE: The minimum idle air rate is set at the factory with a stop screw and is not normally readjusted unless repairs or replacement of the throttle body assembly has occurred. Engine idle speed is computer controlled through the IAC valve and is not adjustable. If there is a complaint of high idle speed, vacuum leaks should be considered the most likely cause. The Electronic Control Module (ECM) controls the Idle Air Control (IAC) valve, and it is less likely that a stalling complaint would be due to incorrect minimum idle speed. If either occurs, refer to Diagnosis by Symptom. If the Minimum Air Rate is suspected, be sure the Idle Air Control (IAC) valve is not "lost" (not actually at the location indicated by current IAC "counts"). The IAC valve could be "lost" if ECM power has been interrupted with the ignition "ON," or the IAC valve has been disconnected with the engine running since the last reset. CAUTION: To prevent engines from running at high speeds, be sure that the ignition is OFF and the vehicle is in PARK or NEUTRAL before connecting Idle Air Control (IAC) assembly, or installing/removing idle air passage plugs. Failure to do this may result in vehicle movement, which can result in personal and/or property damage. MINIMUM IDLE AIR RATE CHECK 1. START engine and bring it to normal operating temperatures 185-212 degrees Fahrenheit (85-100 degrees Celsius). Turn engine OFF. 2. Remove air cleaner assembly. Remove hoses and plug any possible air sources on tube manifold assembly. 3. Disconnect throttle cable. 4. Ground diagnostic "test" terminal in ALDL connector. (jumper A to B) 5. Turn ON ignition, DO NOT START engine. Wait at least 10 seconds (this will allow the IAC pintle to extend and seat in the throttle body). 6. With ignition ON, engine stopped, test terminal still grounded, disconnect IAC valve electrical connector. (This disables the IAC valve in the seated position). Remove the ground from the diagnostic terminal. 7. Connect a scan tool to the ALDL connector and place in open mode. If a tool is not available connect a tachometer to the engine. 8. START engine. With transmission in NEUTRAL, allow engine rpm to stabilize. It may be necessary to depress the accelerator in order to start the engine. 9. Idle speed should be 550 to 650 RPM. Adjust idle stop screw if necessary. To remove the soft plug, puncture with an awl and pry out. Stop Screw Plug Removal 10. If the minimum idle air rate is within 550 to 650 RPM, no further check is required. 11. Turn ignition OFF and reconnect IAC valve electrical connector. 12. Disconnect the SCAN tool or tachometer. 13. The IAC valve will be reset by the computer when the vehicle speed exceeds 43 MPH while the engine speed is above 2000 RPM or when the diagnostic test connector is grounded when the engine RPM is above 2000 RPM. 14. Install air cleaner, adapter, gasket and vacuum hoses. NOTE: The minimum idle air rate is set at the factory with a stop screw, which is covered with a tamper plug. This setting allows enough air flow by the Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Idle Speed > Page 625 throttle valves to cause the IAC valve pintle to be positioned a calibrated number of steps (counts), from the seat, during "controlled" idle operation. If the IAC valve is disconnected and reconnected with the engine running, the idle speed may be wrong. In this case, the IAC valve can be reset by doing the following: The IAC valve will be reset by the computer when the vehicle speed exceeds 43 MPH while the engine speed is above 2000 RPM or when the diagnostic test connector is grounded when the engine RPM is above 2000 RPM. Engine idle speed is computer controlled through the IAC valve, by driving the IAC pintle in and out. Engine idle speed is a funtion of total air flow into the engine based on: IAC valve position, throttle valve opening (idle stop screw), calibrated leakage through the accessories, PCV flow. "Controlled" idle speed is programed into the ECM, which determines the correct IAC valve pintle position to maintain the desired idle speed. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > 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 635 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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: > 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 641 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set Ignition Control Module: All Technical Service Bulletins Engine - Stalls/No Start/Runs Rough/Code 42 Set Number: 91-453-6D Section: 6D Date: NOV. 1991 Corporate Bulletin No.: 136405 ASE No.: A6, A8 Subject: INTERMITTENT DIAGNOSTIC TROUBLE CODE 42 AND/OR DRIVEABILITY Model and Year: 1990-91 CAVALIER, CORSICA AND BERETTA WITH 2.2L ENGINE Condition: Some 1990-91 J and L vehicles equipped with the 2.2L (LM3) engine may intermittently exhibit one or more of the following conditions: * ECM Diagnostic Trouble Code 42 set, with no trouble found. * Engine stalling rough running, with no trouble found. * Intermittent no-start, with no trouble found. * ECM fuse blown, with no trouble found. Cause: DIS (Ignition) module lead wiring may be subject to a rub-through condition at the engine wiring harness bracket where it is mounted at the transaxle case. In addition, a similar condition may also exist on the transaxle case near the same location, from a sharp edge formed during case casting, when equipped with manual transaxle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 647 Correction: Refer to Illustrations for location of repairs. Repair Procedure: - Remove secondary ignition wire bracket and wires, set aside. - Remove clutch cable retainer and cables, set aside. (Manual transaxle only.) - Un-clip engine wiring harness conduit from retainer, pull back conduit to expose harness. - Using common "black" electrical tape (locally attained part), begin taping approximately 5 inches back from the point where the main harness breaks out into 3 smaller harnesses. - While taping to the break-out point, push the individual smaller conduits back and tape up the harnesses as far as possible. * IMPORTANT: Tape wire harness with 4 layers of tape to insure proper insulation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 648 * IMPORTANT: If any wires are worn through enough to short out against each other, if strands of wire are broken, or if an "open" wiring condition is found, refer to Section 8A of the applicable Service Manual for proper wiring repair. - Install wiring harness back into conduit. Before clipping retainer closed, pull the harness towards the center of the vehicle to remove any slack in the harness. This will keep the harness off the transaxle case and away from the transaxle controls. - Clip harness retainer into position. - Reinstall clutch cables and retainer. (Manual transaxle only). - Reinstall secondary ignition cables and bracket. Warranty and Labor Time Information: For taping and repositioning harness: Labor Code: T1789 Labor Time: 0.3 Hours For wiring repair, taping and repositioning of harness: Labor Code: T1789 Labor Time 0.4 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 654 Correction: Refer to Illustrations for location of repairs. Repair Procedure: - Remove secondary ignition wire bracket and wires, set aside. - Remove clutch cable retainer and cables, set aside. (Manual transaxle only.) - Un-clip engine wiring harness conduit from retainer, pull back conduit to expose harness. - Using common "black" electrical tape (locally attained part), begin taping approximately 5 inches back from the point where the main harness breaks out into 3 smaller harnesses. - While taping to the break-out point, push the individual smaller conduits back and tape up the harnesses as far as possible. * IMPORTANT: Tape wire harness with 4 layers of tape to insure proper insulation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 655 * IMPORTANT: If any wires are worn through enough to short out against each other, if strands of wire are broken, or if an "open" wiring condition is found, refer to Section 8A of the applicable Service Manual for proper wiring repair. - Install wiring harness back into conduit. Before clipping retainer closed, pull the harness towards the center of the vehicle to remove any slack in the harness. This will keep the harness off the transaxle case and away from the transaxle controls. - Clip harness retainer into position. - Reinstall clutch cables and retainer. (Manual transaxle only). - Reinstall secondary ignition cables and bracket. Warranty and Labor Time Information: For taping and repositioning harness: Labor Code: T1789 Labor Time: 0.3 Hours For wiring repair, taping and repositioning of harness: Labor Code: T1789 Labor Time 0.4 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair WARNING: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing fuel system components. After relieving system pressure, a small amount of fuel may be released when servicing fuel lines or connections. In order to reduce the chance of personal injury, cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when disconnect is completed. When servicing the fuel system use the following precautions: a. Put a "CAUTION FLAMMABLE" sign in the workshop. b. Be sure shop is supplied with an adequate fire extinguisher. c. Be sure to disconnect battery ground cable before any service work is done. d. Use a suitable container to catch any fuel that may leak from the system during service. e. Always relieve fuel system pressure before disconnecting any lines. f. If the key must be turned ON while servicing the fuel system, always disconnect or disable the ignition, to insure no sparks occur near fuel vapors. g. NEVER turn the ignition on while servicing the fuel system unless the electric fuel pump is disabled. PROCEDURE: 1. Loosen fuel filler cap to relieve tank vapor pressure. 2. Raise the vehicle and disconnect fuel pump electrical connector at fuel tank. 3. Lower vehicle. 4. START engine and RUN until fuel supply remaining in fuel pipes is consumed. Engage starter for 3 seconds to relieve the remaining fuel pressure. 5. Perform required tests or repairs. 6. Raise vehicle and reconnect fuel pump electrical connector at fuel tank. 7. START vehicle for 10 seconds. Shut vehicle OFF and check for leaks. 8. Retighten the fuel tank cap. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Ignition Firing Order Firing Order: Specifications Ignition Firing Order Firing Order ......................................................................................................................................... ....................................................................... 1-3-4-2 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations > Number 1 Cylinder Location Number One Cylinder: Locations Number 1 Cylinder Location NUMBER ONE CYLINDER LOCATION Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug Wire: > 93356D > Oct > 92 > Engine - Miss, Hesitation, or Roughness Spark Plug Wire: Customer Interest Engine - Miss, Hesitation, or Roughness Number: 93-35-6D Section: 6D Date: OCT. 1992 Corporate Bulletin No.: 716404R ASE No.: A1, A8 Subject: ENGINE MISS HESITATION OR ROUGHNESS DUE TO PIERCED SECONDARY IGNITION COMPONENTS Model and Year: 1980-93 ALL PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 87-121, DATED MAY 1987. THE 1989-93 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 87-121 SHOULD BE DISCARDED. During the diagnosis procedure for an engine miss, hesitation or roughness, a spark plug or spark plug wire condition may be suspected. Several types of commercial or homemade diagnostic equipment required the secondary ignition boots or wire to be pierced. This is normally done to check for spark plug firing or to perform a cylinder balance test. Similarly the use of pliers or other such tools to disengage a spark plug boot may pierce or damage the boot or wire. Secondary ignition components should not be pierced for any reason. Piercing a spark plug wire and/or distributor boot may create a condition that will not be immediately apparent. Over time, the hole in the pierced boot may allow a ground path to develop creating a plug misfire condition. Heavily moisture laden air in the vicinity of the pierced boot may accelerate this effect. Piercing a secondary ignition wire creates a gap in the wire's conductive core. This gap is a point of high resistance. The current flow in the wire will increase to compensate for the higher wire resistance. Over time, the wire may fail creating a plug misfire condition. The time required for the condition to appear depends upon the extent of damage to the conductive core. To help prevent future condition that are spark plug wire related, do not pierce or otherwise damage any secondary ignition component. Only use diagnostic equipment containing an inductive pick-up to check for spark plug firing or to perform cylinder balance tests. When disengaging a spark plug boot from the spark plug, twist the flanged boot 1/2 turn then pull on the boot only to remove the wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug Wire: > 93356D > Oct > 92 > Engine - Miss, Hesitation, or Roughness Spark Plug Wire: All Technical Service Bulletins Engine - Miss, Hesitation, or Roughness Number: 93-35-6D Section: 6D Date: OCT. 1992 Corporate Bulletin No.: 716404R ASE No.: A1, A8 Subject: ENGINE MISS HESITATION OR ROUGHNESS DUE TO PIERCED SECONDARY IGNITION COMPONENTS Model and Year: 1980-93 ALL PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 87-121, DATED MAY 1987. THE 1989-93 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 87-121 SHOULD BE DISCARDED. During the diagnosis procedure for an engine miss, hesitation or roughness, a spark plug or spark plug wire condition may be suspected. Several types of commercial or homemade diagnostic equipment required the secondary ignition boots or wire to be pierced. This is normally done to check for spark plug firing or to perform a cylinder balance test. Similarly the use of pliers or other such tools to disengage a spark plug boot may pierce or damage the boot or wire. Secondary ignition components should not be pierced for any reason. Piercing a spark plug wire and/or distributor boot may create a condition that will not be immediately apparent. Over time, the hole in the pierced boot may allow a ground path to develop creating a plug misfire condition. Heavily moisture laden air in the vicinity of the pierced boot may accelerate this effect. Piercing a secondary ignition wire creates a gap in the wire's conductive core. This gap is a point of high resistance. The current flow in the wire will increase to compensate for the higher wire resistance. Over time, the wire may fail creating a plug misfire condition. The time required for the condition to appear depends upon the extent of damage to the conductive core. To help prevent future condition that are spark plug wire related, do not pierce or otherwise damage any secondary ignition component. Only use diagnostic equipment containing an inductive pick-up to check for spark plug firing or to perform cylinder balance tests. When disengaging a spark plug boot from the spark plug, twist the flanged boot 1/2 turn then pull on the boot only to remove the wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Technical Service Bulletins > Page 682 Spark Plug Wire: Specifications Ignition Wire Resistance: 1-15 in. ................................................................................................................................................. .......................................... 3000/10,000 ohms 15-25 in. ..................................................................... .................................................................................................................... 4000/15,000 ohms 25-35 in. ......................................................................................................................................................... ................................ 6000/20,000 ohms OVER 35 in. ......................................................................... .......................................................................................................... 8000/25,000 ohms Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Locations > Spark Plug Wire Routing Ignition Wire Location Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Locations > Spark Plug Wire Routing > Page 685 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plug - Torque Specification Update Spark Plug: Technical Service Bulletins Spark Plug - Torque Specification Update Number: 91-79-6A Section: 6A Date: October 1990 Corporate Bulletin No.: Subject: SPARK PLUG TORQUE SPECIFICATIONS Model and Year: 1990 CELEBRITY 1990-91 BERETTA, CORSICA CAMARO, CAVALIER AND LUMINA, 1990-91 U VAN (APV) TO: ALL CHEVROLET DEALERS When installing spark plugs in the 3.1L engine use the following revised specification in the Service Manuals listed below: Cast Iron or Aluminum Heads, 15 N-m (11 lbs.ft.) 1991 Lumina Pages 6D4 - 4, 5, 7 Cavalier Pages 6A3 - 19 Camaro Pages 6A2 - 31 Pages 6D4 - 7, 9 Corsica/Beretta Pages 6D4 - 3, 6 Pages 6A5 - 24 Lumina (APV) Pages 6A4 - 20, 46 and 6D4 - 6 1990 Celebrity Pages 6D4 - 3, 5 Lumina Pages 6D4 - 4, 5, 6 Cavalier Pages 6A3 - 19 Pages 6D4 - 3 Camaro Pages 6A2 - 30 Pages 6D4 - 7, 8 Corsica/Beretta Pages 6A5 - 20 Pages 6D4 - 2 Lumina (APV) Pages 6A4 - 17, 41 and 6D4 - 6 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plug - Torque Specification Update > Page 690 Spark Plug: Technical Service Bulletins Spark Plugs - Revised Number: 93-03-6D Section: 6D Date: AUGUST 1992 Corporate Bulletin No.: 166001R ASE No.: Al, A6, A8 Subject: NEW DESIGN SPARK PLUGS Model and Yew: 1991-93 ALL PASSENGER CARS AND TRUCKS WITH GASOLINE ENGINES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO., 91-234A-OB, DATED JULY 1992. THE 1992 AND 1993 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 91-234A-OB SHOULD BE DISCARDED. In 1991 GM introduced a new design spark plug for use in all trucks equipped with gas engines. These new design spark plugs have a ceramic insulator which is approximately 1/8 inch longer than the insulator used in previous model years. The longer length spark plugs, which conform to S.A.E. and I.S.O. Engineering guidelines, magnify the problem of cracked insulators because currently, most spark plug sockets are not of sufficient length to properly engage the shell hex. If the spark plug shell hex is not fully engaged in the spark plug socket wrench, the socket may cock at an angle and cause insulator cracking and/or breakage during plug installation or removal. When servicing these new design spark plugs, make sure that the spark plug socket being used is deep enough to accommodate the longer length insulator. The spark plug socket wrench should conform to the proposed S.A.E. and I.S.O. world standards for spark plug socket wrenches. Spark plug socket wrenches that conform to these standards are designed to accept the lengthened spark plugs and allow full engagement of the hex nut on the shell of the spark plug. Use of a spark plug socket which is NOT deep enough may result in the ceramic insulator becoming cracked above the spark plug shell. Note: SOME CRACKS IN THE INSULATOR M" NOT BE VISIBLE. SUCH CRACKS MAY LATER CAUSE A SPARK PLUG TO MISFIRE. SPARK PLUG MISFIRES ARE OFTEN MISDIAGNOSED AS A SLIPPING TRANSMISSION, DEFECTIVE TORQUE CONVERTER CLUTCH, ENGINE IMBALANCE, OR MALFUNCTIONING FUEL SYSTEM. To prevent insulator damage, it is recommended that the proper spark plug socket wrench be used when removing or replacing spark plugs. One such spark plug socket is the Kent-Moore J-39358 spark plug socket. The tool is available from Kent-Moore. For ordering information call 1 -800-345-2233 or write: Kent-Moore SPX Corporation 39784 Little Mack Roseville, MI 48066-2298 Fax: 313-774-9870 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 691 Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ................................................... 0.90 mm (035 in.) Spark Plug Torque ............................................. ......................................................................................................................... 10 - 20 Nm (7 - 15 ft lb) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70% of the highest and no cylinder reading should be less than 689 kPa (100 psi). Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications ROCKER ARM TORQUE Fig. 7 Rocker Arm Cover, Rocker Arms & Pushrod Replacement ^ Rocker Arms are not adjustable on this engine, tighten Rocker Arm Nuts to 30 Nm (22 lbs. ft.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 698 Valve Clearance: Adjustments The Rocker Arms are not adjustable on this engine refer to Rocker Arm / Service and Repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 699 Valve Clearance: Service and Repair The Rocker Arms are not adjustable on this engine refer to Rocker Arm / Service and Repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 704 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 705 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 706 Drive Belt: Service and Repair Serpentine Belt Routing 1. Remove coolant reservoir. 2. Rotate tensioner clockwise with a 15 mm wrench and slide belt from generator pulley. Release tensioner and remove belt. 3. Reverse procedure to install, routing belt as shown in Fig. 22. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 717 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 723 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > A/T - Transaxle Oil Filter Differences Fluid Filter - A/T: Technical Service Bulletins A/T - Transaxle Oil Filter Differences GROUP REF.: Transmission BULLETIN NO.: 477103 DATE: March, 1994 SUBJECT: TRANSAXLE OIL FILTER DIFFERENCES MODELS: 1985-94 PASSENGER CARS AND U VANS WITH 4T60 OR 4T60-E TRANSAXLES TRANSAXLE APPLICATIONS: HYDRA-MATIC 4T60 (RPO ME9) HYDRA-MATIC 4T60-E (RPO M13) TRANSAXLE MODELS: ALL At the start of the 1993 model year, 4T6O transaxle oil filters were revised in appearance. This revision made the 4T60 transaxle oil filter similar in appearance to the 4T60-E transaxle oil filter. Current and previous design 4T6O transaxle oil filters can be used on any 4T6O transaxle. 4T60 and 4T60-E transaxle oil filters are NOT interchangeable. Refer to the current GMSPO catalog for 4T60 and 4T60-E transaxle oil filter part numbers. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair WARNING: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing fuel system components. After relieving system pressure, a small amount of fuel may be released when servicing fuel lines or connections. In order to reduce the chance of personal injury, cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when disconnect is completed. When servicing the fuel system use the following precautions: a. Put a "CAUTION FLAMMABLE" sign in the workshop. b. Be sure shop is supplied with an adequate fire extinguisher. c. Be sure to disconnect battery ground cable before any service work is done. d. Use a suitable container to catch any fuel that may leak from the system during service. e. Always relieve fuel system pressure before disconnecting any lines. f. If the key must be turned ON while servicing the fuel system, always disconnect or disable the ignition, to insure no sparks occur near fuel vapors. g. NEVER turn the ignition on while servicing the fuel system unless the electric fuel pump is disabled. PROCEDURE: 1. Loosen fuel filler cap to relieve tank vapor pressure. 2. Raise the vehicle and disconnect fuel pump electrical connector at fuel tank. 3. Lower vehicle. 4. START engine and RUN until fuel supply remaining in fuel pipes is consumed. Engage starter for 3 seconds to relieve the remaining fuel pressure. 5. Perform required tests or repairs. 6. Raise vehicle and reconnect fuel pump electrical connector at fuel tank. 7. START vehicle for 10 seconds. Shut vehicle OFF and check for leaks. 8. Retighten the fuel tank cap. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance > Page 736 Oil Filter: Technical Service Bulletins Oil Filter - Replacement Information Number: 91-227-6A Section: 6A Date: March 1991 Corporate Bulletin No.: 136105 Subject: CORRECT OIL FILTER Model and Year: 1991 CAVALIER WITH 2.2L ENGINE This bulletin advises dealers and customers of the correct replacement oil filter for the 1991 Cavalier. Disregard information contained in the 1991 Cavalier Owners Manual showing the AC TYPE PF-40 as the replacement oil filter. The proper replacement oil filter for the 1991 Cavalier is the AC TYPE PF-52. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 914083B > Aug > 91 > Power Steering - Shudder/Moan or Vibration Power Steering Line/Hose: Customer Interest Power Steering - Shudder/Moan or Vibration Number: 91-408-3B Section: 3B Date: AUGUST 1991 Corporate Bulletin No.: 133209R ASE No.: A4 Subject: POWER STEERING SHUDDER Model and Year: 1989 CAVALIER, CORSICA AND BERETTA WITH 2.0L AND 2.8L ENGINES 1990 CAVALIER, CORSICA AND BERETTA WITH 2.2L, 2.3L AND 3.1L ENGINES 1991 CAVALIER, CORSICA AND BERETTA WITH 2.2L AND 3.1L ENGINES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-326-3B, DATED AUGUST 1990. THE 1991 MODEL YEAR HAS BEEN ADDED AS WELL AS THE CAVALIER AND CORSICA VEHICLES. ALSO, ADDITIONAL INFORMATION HAS BEEN ADDED. ALL COPIES OF 90-326-3B SHOULD BE DISCARDED. MODELS/YEARS: 1990-91 "J" and "L" w/2.2L (VIN G) engine 1990-91 "J" and "L" w/3.1L (VIN T) engine 1990 "L" w/2.3L (VIN A) engine 1989 "J" and "L" w/2.0L (VIN 1) engine 1989 "J" and "L" w/2.8L (VIN W) engine Condition: Customers may comment about a shudder, moan or vibration that occurs when turning the steering wheel under the following conditions: - Vehicle stopped with brake applied (or moving very slowly) - Vehicle in gear - Engine at idle speed The shudder or moan may occur during parking maneuvers or other situations when the steering wheel is turned while the vehicle is stopped or moving very slowly. It is also sensitive to steering wheel rotational speed as well as engine speed. The shudder is commonly more severe during hot ambient temperatures. Cause: A combination of steering gear valve instability and/or engine firing pulses generating a disturbance that is transmitted through the body structure. Correction: Install a "tuned" power steering return hose and/or high expansion pressure hose between the steering pump and gear. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 914083B > Aug > 91 > Power Steering - Shudder/Moan or Vibration > Page 746 1990-91 "J" w/2.2L (VIN G) engine 1989 "J" w/2.0L (VIN 1) engine This condition may be repaired by installing a "tuned" return hose, P/N 26025260. J-cars built during the 1991 model year already have the "tuned" return hose. If a 1990 2.2L J-car already equipped with a tuned return hose, or a 1991 2.2L J-car exhibits the shudder, install a high expansion pressure hose, P/N 26029284. 1990-91 "J" w/3.1L (VIN T) engine 1989 "J" w/2.8L (VIN W) engine Starting with the following VIN breakpoints, 1991 model vehicles are being built with a new high expansion pressure hose which corrects this condition. Vehicles built BEFORE the VIN breakpoints listed below may be repaired by installing a new high expansion pressure hose, P/N 26026623. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 914083B > Aug > 91 > Power Steering - Shudder/Moan or Vibration > Page 747 (Lordstown) M7117613 1990-91 "L" w/2.2L (VIN G) engine 1989 "L" w/2.0L (VIN 1) engine This condition may be repaired by installing a tuned return hose, P/N 26006690. "L" cars built during the 1991 model year already have the tuned return hose. If a 1990 2.2L L-car already equipped with a tuned return hose, or a 1991 2.2L L-car exhibits the shudder, install a high expansion pressure hose, P/N 26029284. 1990 - 91 "L" w/3.1L (VIN T) engine 1989 "L" w/2.8L (VIN W) engine Starting with the following VIN breakpoints, 1991 model vehicles are being built with a new high expansion pressure hose which repairs this condition. Vehicles built before the VIN breakpoints listed below may be repaired by installing a new high pressure expansion hose, P/N 26028229. (Linden) ME178914 (Wilmington) MY219301 1990 "L" w/2.3L (VIN A) engine Starting with the following VIN breakpoint, 1990 vehicles are equipped with a "tuned" return hose which helps this condition. Vehicles built before this VIN breakpoint, may be repaired by installing a new "tuned" return hose, P/N 26024663. (Wilmington) LY223211 Note: If the above hoses do not repair the shudder condition, please contact Technical Assistance. Parts are currently available from GMSPO. Labor Operation Number: Pressure Hose E8622 Labor Time : See Current Labor Time Guide Trouble Code : 92 Labor Operation Number: Return Hose E8623 Labor Time : See Current Labor Time Guide Trouble Code : 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 914083B > Aug > 91 > Power Steering - Shudder/Moan or Vibration Power Steering Line/Hose: All Technical Service Bulletins Power Steering - Shudder/Moan or Vibration Number: 91-408-3B Section: 3B Date: AUGUST 1991 Corporate Bulletin No.: 133209R ASE No.: A4 Subject: POWER STEERING SHUDDER Model and Year: 1989 CAVALIER, CORSICA AND BERETTA WITH 2.0L AND 2.8L ENGINES 1990 CAVALIER, CORSICA AND BERETTA WITH 2.2L, 2.3L AND 3.1L ENGINES 1991 CAVALIER, CORSICA AND BERETTA WITH 2.2L AND 3.1L ENGINES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-326-3B, DATED AUGUST 1990. THE 1991 MODEL YEAR HAS BEEN ADDED AS WELL AS THE CAVALIER AND CORSICA VEHICLES. ALSO, ADDITIONAL INFORMATION HAS BEEN ADDED. ALL COPIES OF 90-326-3B SHOULD BE DISCARDED. MODELS/YEARS: 1990-91 "J" and "L" w/2.2L (VIN G) engine 1990-91 "J" and "L" w/3.1L (VIN T) engine 1990 "L" w/2.3L (VIN A) engine 1989 "J" and "L" w/2.0L (VIN 1) engine 1989 "J" and "L" w/2.8L (VIN W) engine Condition: Customers may comment about a shudder, moan or vibration that occurs when turning the steering wheel under the following conditions: - Vehicle stopped with brake applied (or moving very slowly) - Vehicle in gear - Engine at idle speed The shudder or moan may occur during parking maneuvers or other situations when the steering wheel is turned while the vehicle is stopped or moving very slowly. It is also sensitive to steering wheel rotational speed as well as engine speed. The shudder is commonly more severe during hot ambient temperatures. Cause: A combination of steering gear valve instability and/or engine firing pulses generating a disturbance that is transmitted through the body structure. Correction: Install a "tuned" power steering return hose and/or high expansion pressure hose between the steering pump and gear. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 914083B > Aug > 91 > Power Steering - Shudder/Moan or Vibration > Page 753 1990-91 "J" w/2.2L (VIN G) engine 1989 "J" w/2.0L (VIN 1) engine This condition may be repaired by installing a "tuned" return hose, P/N 26025260. J-cars built during the 1991 model year already have the "tuned" return hose. If a 1990 2.2L J-car already equipped with a tuned return hose, or a 1991 2.2L J-car exhibits the shudder, install a high expansion pressure hose, P/N 26029284. 1990-91 "J" w/3.1L (VIN T) engine 1989 "J" w/2.8L (VIN W) engine Starting with the following VIN breakpoints, 1991 model vehicles are being built with a new high expansion pressure hose which corrects this condition. Vehicles built BEFORE the VIN breakpoints listed below may be repaired by installing a new high expansion pressure hose, P/N 26026623. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 914083B > Aug > 91 > Power Steering - Shudder/Moan or Vibration > Page 754 (Lordstown) M7117613 1990-91 "L" w/2.2L (VIN G) engine 1989 "L" w/2.0L (VIN 1) engine This condition may be repaired by installing a tuned return hose, P/N 26006690. "L" cars built during the 1991 model year already have the tuned return hose. If a 1990 2.2L L-car already equipped with a tuned return hose, or a 1991 2.2L L-car exhibits the shudder, install a high expansion pressure hose, P/N 26029284. 1990 - 91 "L" w/3.1L (VIN T) engine 1989 "L" w/2.8L (VIN W) engine Starting with the following VIN breakpoints, 1991 model vehicles are being built with a new high expansion pressure hose which repairs this condition. Vehicles built before the VIN breakpoints listed below may be repaired by installing a new high pressure expansion hose, P/N 26028229. (Linden) ME178914 (Wilmington) MY219301 1990 "L" w/2.3L (VIN A) engine Starting with the following VIN breakpoint, 1990 vehicles are equipped with a "tuned" return hose which helps this condition. Vehicles built before this VIN breakpoint, may be repaired by installing a new "tuned" return hose, P/N 26024663. (Wilmington) LY223211 Note: If the above hoses do not repair the shudder condition, please contact Technical Assistance. Parts are currently available from GMSPO. Labor Operation Number: Pressure Hose E8622 Labor Time : See Current Labor Time Guide Trouble Code : 92 Labor Operation Number: Return Hose E8623 Labor Time : See Current Labor Time Guide Trouble Code : 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 914131A > Sep > 91 > Heater - Low Output Heater Control Valve: All Technical Service Bulletins Heater - Low Output Number: 91-413-1A Section: 1A Date: SEPT. 1991 Corporate Bulletin No.: 131104 ASE No.: A7 Subject: LOW HEAT DELIVERY RELATED DIAGNOSIS REVISED PROCEDURE Model and Year: 1989-91 CAVALIER On customer comments of low heater output on 1989-91 J cars, before replacing a suspected defective engine cooling thermostat, proper diagnosis of the condition must be performed to avoid the possibility of a repeat repair. Follow "Diagnosis" as shown in Section 1A/1B of the appropriate Service Manual. After completing the diagnosis, use the following as a guide to the next corrective step: ^ If the diagnosis indicates a defective thermostat, refer to Section 6C for replacement. ^ If the diagnosis indicates a defective temperature control cable, refer to Section 1A/1B for replacement. ^ If the diagnosis indicates the temperature control cable is no longer "snapped" into its retainer, refer to "Temperature Control Cable Repair" in the 1991 Service Manual, Sections 1A/1B. ^ If the diagnosis indicates that the temperature control cable is out of adjustment, refer to the following procedure to repair. TEMPERATURE CONTROL CABLE ADJUSTMENT PROCEDURE Condition: 1. "Spring back" off full "hot" temperature control position (or not attaining full "cold" temperature door position). Condition: 2. "Spring back" off full "cold" temperature control position (or not attaining full "hot" temperature door position). Cause: The temperature control cable "clip" needs adjustment. Refer to the illustration for correct gripping of the "clip" during adjustment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 914131A > Sep > 91 > Heater - Low Output > Page 760 Correction For Number: 1. Grip "clip" at module end of cable while pulling temperature control lever to "hot" position. Correction For Number: 2. Grip "clip" at module end of cable while pushing temperature control lever to "cold" position. NOTICE: FAILURE TO GRIP "CLIP" CORRECTLY WILL DAMAGE ITS ABILITY TO HOLD POSITION ON THE CABLE. THE TEMPERATURE CONTROL CABLE MUST BE REPLACED IF "CLIP" RETENTION FAILS. Verify correct adjustment after repair by observing for no, or very liftle, "spring back" of the temperature control lever and listening for temperature door "slam" when the control lever is moved to full hot and cold positions quickly. Please note your copies of the Service Manuals in Sections 1A and 1B, under "Temperature Control Cable", with these new adjustment instructions. Warranty and Labor Information: Use the appropriate failure code for each occurrence. For thermostat or temperature control cable replacement, use current applicable warranty and labor information. For temperature cable repair at the heater control, use current heater warranty and labor information. For temperature control repair at the HVAC module or cable adjustment: Labor Operation Number: D0400 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 914131A > Sep > 91 > Heater - Low Output > Page 766 Correction For Number: 1. Grip "clip" at module end of cable while pulling temperature control lever to "hot" position. Correction For Number: 2. Grip "clip" at module end of cable while pushing temperature control lever to "cold" position. NOTICE: FAILURE TO GRIP "CLIP" CORRECTLY WILL DAMAGE ITS ABILITY TO HOLD POSITION ON THE CABLE. THE TEMPERATURE CONTROL CABLE MUST BE REPLACED IF "CLIP" RETENTION FAILS. Verify correct adjustment after repair by observing for no, or very liftle, "spring back" of the temperature control lever and listening for temperature door "slam" when the control lever is moved to full hot and cold positions quickly. Please note your copies of the Service Manuals in Sections 1A and 1B, under "Temperature Control Cable", with these new adjustment instructions. Warranty and Labor Information: Use the appropriate failure code for each occurrence. For thermostat or temperature control cable replacement, use current applicable warranty and labor information. For temperature cable repair at the heater control, use current heater warranty and labor information. For temperature control repair at the HVAC module or cable adjustment: Labor Operation Number: D0400 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations Brake Fluid: Technical Service Bulletins Brake Fluid - Level & Filling Recommendations File In Section: 05 - Brakes Bulletin No.: 00-05-22-004 Date: May, 2000 INFORMATION Subject: Brake Fluid Level and Filling Recommendations Models: 2001 and Prior Passenger Cars and Trucks Many dealers and after-market repair shops advertise multi-point fluid "top-ups" in conjunction with oil changes or regular maintenance packages. These offers often include adding brake fluid to the master cylinder reservoir. There are only two reasons why the brake fluid level in the brake reservoir might go down. The first is that the brake fluid level goes down an acceptable level during normal brake lining wear. When the linings are replaced, the fluid will return to it's original level. The second possible reason for a low fluid level is that fluid is leaking out of the brake system. If fluid is leaking, the brake system requires repair and adding additional fluid will not correct the leak. If the system was properly filled during delivery of the vehicle, no additional fluid should be required under most circumstances between brake pad and/or shoe replacements. This information can be reinforced with the customer by referring them to the Brake Fluid section of their vehicle's Owner's Manual. Guidelines GM vehicles have incorporated a variety of brake fluid reservoir styles. The following guidelines are restricted to the plastic bodied fluid reservoirs and do not affect the original service recommendations for the older style metal bodied units. You may encounter both black plastic and translucent style reservoirs. You may have reservoirs with: ^ A MAX fill mark only ^ A MIN fill mark only ^ Both MAX and MIN marks The translucent style reservoirs do not have to have the covers removed in order to view the fluid level. It is a good practice not to remove the reservoir cover unless necessary to reduce the possibility of contaminating the system. Use the following guidelines to assist in determining the proper fluid level. Important: When adding brake fluid, use Delco Supreme II(R) Brake Fluid, GM P/N 12377967 or equivalent brand bearing the DOT-3 rating only. Important: At no time should the fluid level be allowed to remain in an overfilled condition. Overfilling the brake reservoir may put unnecessary stress on the seals and cover of the reservoir. Use the following guidelines to properly maintain the fluid level. If the reservoir is overfilled, siphon out the additional fluid to comply with the guidelines below. Important: If under any circumstance the brake fluid level is extremely low in the reservoir or the BRAKE warning indicator is illuminated, the brake system should be checked for leaks and the system repaired in addition to bringing the fluid level up to the recommended guidelines outlined below. A leaking brake system will have reduced braking performance and will eventually not work at all. Important: Some vehicles have reservoirs that are very sensitive to brake fluid levels and may cause the BRAKE indicator to flicker on turns as the fluid approaches the minimum required level. If you encounter a vehicle with this concern, increase the fluid level staying within the guidelines outlined below. ^ If the reservoir has a MAX level indicator, the reservoir should be returned to the MAX marking only at the time new brake pads and/or shoes are installed. If the reservoir fluid level is at the half-way point or above do not attempt to add additional brake fluid during routine fluid checks. ^ If the reservoir has both MAX and MIN indicators, the fluid level should be maintained above the MIN indicator during routine fluid checks and returned to the MAX indication only after new brake pads and/or shoes are installed. ^ For reservoirs with only a MIN indication, the fluid level should be maintained above the MIN indicator during routine fluid checks. Return the Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations > Page 772 reservoir fluid level to full only after installing new brake pads and/or shoes. A full reservoir is indicated on translucent, snap cover reservoirs by a fluid level even with the top level of the view window imprinted into the side of the reservoir. On screw top models in black or translucent plastic, the full level is just below the bottom of the filler neck. Parts Information Part Number Description 12377967 Brake Fluid Parts are currently available from GMSPO. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications Fill the clutch master cylinder to the "Full" or "MAX" mark on the reservoir. Do not overfill. Caution: Should accidental spillage occur, rinse the area thoroughly with water. Pay special attention to any electrical wires, parts, harnesses, rubber or painted surfaces. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 777 Clutch Fluid: Fluid Type Specifications Hydraulic Clutch Fluid ........................................................................................................................................ GM P/N 12345347 or DOT 3 Brake Fluid Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information > Page 782 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information > Page 783 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information > Page 784 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information > Page 785 Coolant: Technical Service Bulletins Cooling System - Use of Recycled Engine Coolant Number: 91-235-6B Section: 6B Date: MARCH 1991 Corporate Bulletin No.: 116201 Subject: USE OF RECYCLED ENGINE COOLANT Model and Year: ALL PASSENGER CARS AND TRUCKS With the current emphasis on environmental issues and disposal of waste, significant attention is being given to the recycling of engine coolant. Many coolant recycling systems are being aggressively marketed today, ranging from very complex distillation (stationary) to straightforward filtration (mobile). As stated in previous service bulletins, General Motors does not endorse the use of recycled engine coolants in our products at this point in time. Recycling engine coolant is a very complex procedure and consequently will require a significant amount of research to determine which of the many processes is acceptable by General Motors. While we understand the growing concern being placed on (spent) engine coolant disposal, it is imperative that the quality of engine coolants being used in General Motors vehicles is not affected in any way. General Motors is addressing the issue of recycled engine coolants for the combined benefit of our dealers, vehicle owners, and the environment. Over the next several months General Motors will conduct an experiment designed to evaluate both distillation and "on-site" recycling processes. The results of this experiment will be provided to all dealers (spring, 1991) and will outline which process(es) is acceptable to General Motors. It is essential that recycled engine coolant not be used in any General Motors products as communicated in previous bulletins. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information > Page 786 Coolant: Technical Service Bulletins Coolant - Specification/Usage Number: 91-62-6B Section: 6B Date: August 1990 Corp. Bulletin No.: 066202 Subject: COOLANT USAGE Model and Year: ALL 1988-91 PASSENGER CARS AND TRUCKS TO: ALL CHEVROLET DEALERS THIS INFORMATION SUPERSEDES INFORMATION PROVIDED BY GMSPO IN PARTS AND ACCESSORIES BULLETINS IB NO. 90-55 AND 90-60 AND INFORMATION PROVIDED IN VARIOUS TRUCK SERVICE AND OWNERS MANUALS AND SHOULD BE USED TO DETERMINE CORRECT COOLANT USAGE IN LIGHT AND MEDIUM DUTY TRUCK APPLICATIONS. GM coolant specification 6038-M or 1899-M (P/N 1052103) is for use in all light duty trucks with gasoline or diesel engines. This coolant features a low silicate formulation and is intended only for use in engines that have cylinder heads and cylinder blocks made of cast iron. GM coolant specification 1825-M or 6043-M (P/N 1052753) which until recently has been the recommended coolant for light duty trucks has been superseded by GM coolant 6038-M or 1899-M (P/N 1052103) in cast iron truck engines. GM coolant specification 1825-M has a higher silicate formulation which is recommended for all passenger car engines with cylinder heads or cylinder blocks made of aluminum. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information > Page 787 Coolant: Technical Service Bulletins Coolant - Information on Propylene Glycol Usage File In Section: 6 - Engine Bulletin No.: 43-62-01B Date: April, 1995 Subject: Propylene Glycol Engine Coolant Models: 1994 and Prior Passenger Cars and Trucks This bulletin is being revised to reflect most current information on propylene glycol engine coolant. Please discard Corporate Bulletin Number 4362O1A (Group Reference 6 - Engine). General Motors has been reviewing data supplied on the performance of propylene glycol engine coolant in GM vehicles. It is our conclusion that propylene glycol engine coolant will perform adequately under most vehicle operating conditions. As a result, propylene glycol engine coolant (meeting performance specification GM 1825M) may be used in GM vehicles and will not affect the warranty coverage. Prior to adding propylene glycol engine coolant to the cooling system, all the existing (ethylene glycol) coolant must be removed. This can be accomplished either by utilizing water-based coolant flushing equipment or "waterless quick change" equipment available in the GMDE program. As with any coolant change procedure, be sure to thoroughly purge the heater core and block as well as the radiator before attempting to convert the system to propylene glycol coolant. Freeze/Boil point levels are different for propylene glycol than for ethylene glycol engine coolant. To accurately determine freeze/boil protection level, it is imperative that coolants not be mixed. Removing all the used coolant as previously discussed resolves this concern. Freeze protection of propylene glycol cannot be determined using a standard hydrometer. Rather, a refractometer or test strip must be used. Propylene glycol engine coolants may be recycled in the same manner as conventional ethylene glycol coolant. No adverse effects will be encountered if these coolants are mixed prior to recycling, however, the ratio of propylene glycol coolant to ethylene glycol coolant should be kept low to minimize the effects on freeze point measurements. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information > Page 788 Coolant: Technical Service Bulletins Cooling System - Reconstituted Anti-Freeze Information Number: 90-49-6B Section: 6B Date: August 1989 Corporate Bulletin No.: 930107 Subject: RECONSTITUTED ANTI-FREEZE Model and Year: ALL MODELS, ALL MODEL YEARS TO: ALL CHEVROLET DEALERS This bulletin provides information on "reconstituted anti-freeze". It has been brought to our attention that a number of manufacturers claim to have the capability of reconstituting engine coolant on site. At this time, General Motors does not endorse this practice or any equipment. Anti-freeze recycling is a very complex issue. In use as an engine coolant, ethylene glycol becomes oxidized producing a very degraded and deteriorated substance. Contamination by other automotive fluids during draining, handling and storage is also a major detriment to the reclaiming process. There is no additive we are aware of that can be merely put into used coolant that will restore it to an acceptable state. Typically, a multi-million dollar facility, utilizing sophisticated technology with distillation capabilities along with appropriate quality control would be required to adequately process used coolant to bring it to GM specifications. Disposal of all chemical products should be done in accordance with all applicable federal, state and local laws and regulations. Review engine coolant substitutes Dealer Service Bulletin No. 89-57-6B, dated January 1989. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Page 789 Coolant: Specifications MAKE, YEAR & MODEL LITERS QUARTS CHEVROLET CAVALIER 1992 V6 12.4 13.1 1992 4-cyl 8.7 9.2 1991 V6 13.5 14.2 1991 4-cyl 11.1 11.7 1990 V6 10.4 11.0 1990 4-cyl 8.0 8.5 1989-85 4-cyl 9.1 9.6 V6 10.5 11.1 1984-83 All 9.2 9.7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 794 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 795 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 796 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 797 Fluid - A/T: Technical Service Bulletins A/T - DEXRON III Fluid Introduction File In Section: 0 - General Information Bulletin No.: 57-02-01 Date: March, 1995 SERVICE MANUAL UPDATE Subject: Section 0 - General Information - DEXRON(R)-III Transmission Fluid Introduction Models: 1995 and Prior Passenger Cars and Trucks General Motors has phased in a new automatic transmission fluid, DEXRON(R)-III, that does not need replacing under normal service. DEXRON(R)-III is designed to help the transmission deliver the best possible performance under all conditions. Refer to Figure 1. The improvements in DEXRON(R)-III include better friction stability, more high temperature oxidation stability and better material compatibility. DEXRON(R)-III has the same low temperature fluidity as DEXRON(R)-IIE, for better transmission performance in cold weather. DEXRON(R)-IIE and DEXRON(R)-III are fully compatible. DEXRON(R)-III is fully compatible with any General Motors passenger vehicle or light truck with automatic transmission and built since 1949. Dealers should require their supplier to include the DEXRON(R)-III license number on all automatic transmission fluid invoices. Starting February 1, 1994 DEXRON(R)-III was phased into all North American assembly plants. DEXRON(R)-III fluid is available from GMSPO (see fluid numbers below): U.S. 1 Quart 12346143 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 798 1 Gallon 12346144 55 Gallon 12346145 In Canada 1 Liter 10952622 4 Liter 10952623 200 Liter 10952624 The 1995 Automatic Transmission/Transaxle fluid change intervals are the following: (1994 and prior should use the schedules as written in the Owner's Manual.) 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 car or delivery service. Change the fluid and filter every 50,000 miles (63,000 km). If the vehicle is not used mainly under any of these conditions, the fluid and filter do not require periodic changing for vehicles under 8,600 GVWR. Vehicles over 8,600 GVWR change the fluid and filter every 50,000 miles (83,000 km) regardless of driving conditions. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 799 Fluid - A/T: Technical Service Bulletins A/T - Fluid Level Checking Procedure Number: 93-98-7A Section: 7A Date: FEB. 1993 Corporate Bulletin No.: 377101 ASE No.: A2 Subject: AUTOMATIC TRANSAXLE FLUID LEVEL CHECKING PROCEDURE Model and Year: 1990 CELEBRITY 1990-93 CAVALIER, CORSICA, BERETTA AND LUMINA 1990-93 LUMINA APV TRANSMISSION APPLICATIONS: 1990-93 HYDRA-MATIC 3T40 (RPO MD9) 1990-93 HYDRA-MATIC 4T60 (RPO ME9) 1991-93 HYDRA-MATIC 4T60-E (RPO M13) 1993 HYDRA-MATIC 4T80-E (RPO MH1) TRANSMISSION MODELS: All SUBJECT: Automatic Transaxle Fluid Level Checking Procedure VEHICLE APPLICATIONS: A, J, L, W Cars AND U-VAN BULLETIN COVERS: Transaxle fluid level checking and condition information. This updates all information previously published for 1990-93 HYDRA-MATIC 3T40, 4T60, 4T60-E and 4T80-E transaxles. Due to enhancement of assembly plant fluid fill capabilities, it is especially important to warm the transaxle up to operating temperature before determining that fluid needs to be added. If the transaxle fluid is close to operating temperature, the fluid level may read slightly below the "ADD" mark. DO NOT ADD FLUID UNLESS THE TRANSAXLE IS AT OPERATING TEMPERATURE AND THE DIPSTICK SHOWS FLUID LEVEL IS BELOW THE CROSSHATCHED AREA. TRANSAXLE FLUID LEVEL INFORMATION: Checking fluid level and condition (color and smell) at recommended service intervals will provide early diagnosis information about the transaxle. This information may then be used to correct a condition that, if not detected early, could result in major transaxle repairs. When adding or changing fluid, use only DEXRON(R)-IIE. Refer to Maintenance and Lubrication (Service Manual Section 0B) for maintenance information and service intervals. NOTICE: Do not overfill. Overfilling will cause foaming, loss of fluid, shift complaints and possible damage to the transaxle. Fluid level should only be checked when it reaches a normal operating temperature of 82-93 degrees C (180-200 degrees F). This temperature is reached after approximately 24 km (15 miles) of driving. TRANSAXLE FLUID COLOR: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 800 Fluid color will be red when new. IMPORTANT: When new, automatic transaxle fluid is red in color. The red dye is added so the assembly plant can identify it as transaxle fluid and distinguish # from engine oil or antifreeze. The red dye is not an indicator of fluid quality and is not permanent. As the vehicle is driven the fluid will begin to look darker in color. The color may eventually appear light brown. A dark brown color with a burnt odor may indicate fluid deterioration and signal a need for a transaxle fluid change. TRANSAXLE FLUID CHECKING PROCEDURE: 1. Start engine and drive vehicle until the transaxle reaches operating temperature of 82-93 degrees C (180-200 degrees F). This temperature is reached after about 24 km (15 miles) of driving. Inaccurate fluid level readings will result if the fluid level is checked immediately after the vehicle has been operated under certain conditions: - When outside temperatures are above 32 degrees C (90 degrees F) - At sustained high speeds - In heavy city traffic during hot weather - Towing a trailer - In commercial service such as taxi or police use If the vehicle has been operated under any of these conditions, shut the engine off and allow the vehicle to cool for thirty (30) minutes. Then restart the vehicle and continue with step two. 2. Stop vehicle on level ground and put the gear selector in "P" (Park). 3. Set parking brake. 4. With your foot on the brake pedal, move the shift lever through each gear range, pausing for about three seconds in each range. Then put the gear selector back in "P" (Park). 5. Let the engine idle for three to five minutes. 6. Pull out the dipstick and wipe it with a clean rag or towel. 7. Push it back in all the way, wait three seconds and pull it back out. 8. Check both sides of the dipstick and read the lower level. The fluid should be in the crosshatched "HOT" area. IMPORTANT: The fluid level is ok if it is any where within the cross hatched area. It does not have to beat the top of the cross hatched area. Do not add fluid unless the fluid level is below the crosshatched area. 9. If the fluid level is where it should be, push the dipstick back in all the way. ADDING TRANSAXLE FLUID: If fluid level is low (after properly performing the checking procedure above) add only enough fluid to bring the level into the crosshatched area. It doesn't take much fluid, generally less than a pint. Don't overfill. Remember that the level does not need to be at the top of the crosshatched area to be correct. After adding fluid, always recheck the fluid level as described in the above procedure. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications VIN G, Oil Capacity VIN G, Oil Capacity Oil Pan Only 4 qt (US) After Overhaul Less Torque Converter Drain 6 qt (US) With Torque Converter Drain 9 qt (US) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 803 Fluid - A/T: Fluid Type Specifications Lubricant Type ..................................................................................................................................... .................................................................. Dexron II Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 804 Fluid - A/T: Service and Repair NOTE: Use only Dexron IIE automatic transmission fluid To check fluid, drive vehicle for at least 15 minutes to bring fluid to operating temperature (200°F). With vehicle on a level surface and engine idling in Park and parking brake applied, the level on the dipstick should be at the ``Full'' mark. To bring the fluid level from the ADD mark to the FULL mark requires one pint of fluid. If vehicle cannot be driven sufficiently to bring fluid to operating temperature, the level on the dipstick should be between the two dimples on the dipstick with fluid temperature at 70°F. Note that the two dimples are located above the FULL mark. If additional fluid is required, use only Dexron II automatic transmission fluid. An early change to a darker color from the usual red color and or a strong odor that is usually associated with overheated fluid is normal and should not be considered as a positive sign of required maintenance or unit failure. When adding fluid, do not overfill, as foaming and loss of fluid through the vent may occur as the fluid heats up. Also, if fluid level is too low, complete loss of drive may occur especially when cold, which can cause transmission failure. Every 100,000 miles, the oil should be drained, the oil pan removed, the screen cleaned and fresh fluid added. For vehicles subjected to more severe use such as heavy city traffic especially in hot weather, prolonged periods of idling or towing, this maintenance should be performed every 15,000 miles. 1. Raise and support vehicle, then position drain pan under oil pan. 2. Remove front and side oil pan attaching bolts, then loosen rear pan attaching bolts. 3. Carefully pry oil pan loose from transaxle case and allow fluid to drain. 4. Remove remaining attaching bolt, oil pan and gasket. Thoroughly clean pan before reinstalling. 5. Remove and discard screen and O-ring seal. 6. Install replacement screen and O-ring seal, locating screen against dipstick stop. 7. Install gasket on oil pan, then install pan and torque attaching bolts to 8 ft. lbs. 8. Lower vehicle and add approximately 4 qts. of fluid. 9. With selector in park, parking brake applied and engine at idle speed and operating temperature, check fluid level and add fluid as necessary. Do not race engine. Move shift lever through ranges, then back to ``Park'' position. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications VIN G, Oil Capacity VIN G, Oil Capacity Isuzu 5 Speed 5.4 pt (US) Muncie 5 Speed 5 pt (US) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 809 Fluid - M/T: Fluid Type Specifications HM-282 and 5TM40 Lubricant Type ............................................................................................................................................ Synchromesh Trans Fluid (Part No. 12345349) GM-Isuzu 5 Speed Manual Transaxle Lubricant Type ............................................................................................................................................ Synchromesh Trans Fluid (Part No. 12345349) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 814 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 815 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil without Filter ....................................................................................................................... ............................................... 4.0 quarts (3.8 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold Power Steering Fluid: Customer Interest P/S - Reduced Assist When Cold Group Ref.: Steering/Suspension Bulletin No.: 033206 Date: March 1994 SUBJECT: REDUCED POWER STEERING ASSIST AT LOW AMBIENT TEMPERATURES (NEW POWER STEERING FLUID) MODELS: 1994 AND PRIOR PASSENGER CARS AND LIGHT DUTY TRUCKS Applications: Appropriate for all passenger vehicles, but particularly beneficial in 1980 and later FWD Models equipped with Power Rack and Pinion Steering. CONDITION: Comments of reduced power steering assist at low ambient temperatures (approximately 10°F and lower) may be noted by some vehicle operators when turning the steering wheel in BOTH the right and left direction during warm-up after cold start. All vehicles with power steering exhibit this condition to varying degrees, but condition may be more noticeable with power rack and pinion steering systems that typically have longer hoses and cooler lines. Note: This condition, which is related to power steering fluid viscosity, should not, however, be confused with conditions having similar symptoms such as that described divisional Special Policy numbers listed: CAUSE: In cold weather, power steering fluid thickens in the same manner as any other petroleum-based oil or fluid. Upon cold starting, the fluid resists movement through the system and the driver senses reduced power assist (sometimes referred to as "stiff steer"). As the vehicle operates and fluid circulates through the power steering system, the fluid warms and thins to its normal operating viscosity. CORRECTION: Saginaw Division has developed a new Low Temperature Climate Service Fluid for use in cold climates. Compared with conventional power steering fluid, this new fluid flows better at low temperatures and resists the thickening which contributes to reduced power assist upon start up. RACK AND PINION STEERING SYSTEMS Reduced power assist upon cold weather starting may be more noticeable in Power Rack and Pinion steering systems that may contain six or more feet of Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold > Page 826 pressure and return hose along with long cooler lines. Such long systems contain greater volumes of fluid and vehicles so equipped tend to have longer periods of reduced power assist. The new fluid performs particularly well with current designed Rack and Pinion steering systems and special remanufactured Rack and Pinion Steering Assemblies. PARTS INFORMATION: Low Temperature Climate Service Fluid is available from GMSPO. Order as: Parts are currently available from GMSPO. SERVICE PROCEDURE: The power steering fluid replacement procedure is a two-stage process: first, flushing the old fluid from the system with new fluid; and second, bleeding the system to remove any trapped air. The two sequences outline the steps in each procedure. FLUSHING THE POWER STEERING SYSTEM 1. Raise the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the fluid return line at the pump reservoir inlet connector. 3. Plug the inlet connector port on the pump reservoir. 4. Position the fluid return line toward a large container in order to catch the draining fluid. 5. While a second person fills the reservoir with new Low Temperature Climate Service Fluid, start and run the engine at idle. 6. Turn the steering wheel from stop to stop. NOTICE: Do not hold the wheel against stops while flushing the system, Holding steering wheel against wheel stops will cause high system pressure, overheating, and damage to the pump and/or gear. 7. Continue draining until all of the old fluid is cleared from the power steering system. Addition of approximately 1 quart of new fluid will be required to flush system. 8. Unplug pump reservoir inlet and reconnect return line. 9. Turn engine off, and fill reservoir to the "Full Cold" mark. 10. Continue with following procedure "Bleeding the Power Steering System". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold > Page 827 BLEEDING THE POWER STEERING SYSTEM After replacing the fluid or servicing the power steering hydraulic system, you must bleed air from the system. Air in the system prevents an accurate fluid level reading, causes pump cavitation noise and over time could damage the pump. To bleed the power steering system proceed as follows: 1. Begin with the engine off, front wheels off the ground, and wheels turned all the way to the left. 2. Add Low Temperature Climate Service Fluid to the "FULL COLD" mark on the fluid level indicator. 3. Bleed the system by turning the wheels from side to side without hitting stops. Important: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold > Page 828 This may require turning the wheels from side to side twenty times. On systems with long return lines or fluid coolers, turning steering wheel lock-to-lock forty times may be required. Keep the fluid level at the "FULL COLD" mark. Fluid with air In it has a light tan appearance. This air must be eliminated from the fluid before normal steering action can be obtained. 4. Start the engine. With the engine idling, recheck the fluid level. If necessary, add fluid to bring the level to the "FULL COLD" mark. 5. Return the wheels to the center position. Lower front wheels to the ground. Continue running the engine for two or three minutes. 6. Test the vehicle to be sure the steering functions normally and is free from noise. Important: Inspect for fluid leakage at connection points along the power steering system. 7. Recheck the fluid level as described in Steps 3 and 4 except that the fluid level should now be up to the "FULL HOT" mark after the system has stabilized at its normal operating temperature. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid: > 912083B > Feb > 91 > Power Steering - Reduced Assist At Low Temperatures Power Steering Fluid: Customer Interest Power Steering - Reduced Assist At Low Temperatures Number: 91-208-3B Section: 3B FEBRUARY 1991 Date: Corporate Bulletin No.: 033206R Subject: REDUCED POWER STEERING ASSIST AT LOW AMBIENT TEMPERATURES Model and Year: ALL 1980-91 PASSENGER CARS Applications Appropriate for all passenger vehicles, but particularly beneficial in 1980 and later FWD Models equipped with Power Rack and Pinion Steering. CONDITION Comments of reduced power steering assist at low ambient temperatures (approximately 10 degrees Fahrenheit and lower) may be noted by some vehicle operators when turning the steering wheel in BOTH the right and left direction during warm-up after cold start. All vehicles with power steering exhibit this condition to varying degrees, but condition may be more noticeable with power rack and pinion steering systems that typically have longer hoses and cooler lines. Note: This condition, which is related to power steering fluid viscosity, should not, however, be confused with conditions having similiar symptoms such as that described in divisional bulletins indicated below, related to internal steering gear fluid by-pass. Chevrolet # 88-417-3B CAUSE: In cold weather, power steering fluid thickens in the same manner as any other petroleumbased oil or fluid. Upon cold starting, the fluid resists movement through the system and the driver senses reduced power assist (sometimes referred to as "stiff steer"). As the vehicle operates and fluid circulates through the power steering system, the fluid warms and thins to its normal operating viscosity. CORRECTION: Saginaw Division has developed a new Low Temperature Climate Service Fluid for use in cold climates. Compared with conventional power steering fluid, this new fluid flows better at low temperatures and resists the thickening which contributes to reduced power assist upon start up. RACK AND PINION STEERING SYSTEMS Reduced power assist upon cold weather starting may be more noticeable in Power Rack and Pinion steering systems that may contain six or more feet of pressure and return hose along with long cooler lines. Such long systems contain greater volumes of fluid and vehicles so equipped tend to have longer periods of reduced power assist. The new fluid performs particularly well with current designed Rack and Pinion steering systems and special remanufactured Rack and Pinion Steering Assemblies. PARTS INFORMATION: Low Temperature Climate Service Fluid is available from GMSPO. Order as: Container Size Part Number 16 ounce 12345866 32 ounce 12345867 Parts are currently available from GMSPO. SERVICE PROCEDURE: The power steering fluid replacement procedure is a two-stage process: first, flushing the old fluid from the system with new fluid; and second, bleeding the system to remove any trapped air. The following two sequences outline the steps in each procedure. FLUSHING THE POWER STEERING SYSTEM Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid: > 912083B > Feb > 91 > Power Steering - Reduced Assist At Low Temperatures > Page 833 1. Raise the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the fluid return line at the pump reservoir inlet connector. 3. Plug the inlet connector port on the pump reservoir. 4. Position the fluid return line toward a large container in order to catch the draining fluid. 5. While a second person fills the reservoir with new Low Temperature Climate Service Fluid, start and run the engine at idle. 6. Turn the steering wheel from stop to stop. NOTICE: Do not hold the wheel against stops while flushing the system. Holding steering wheel against wheel stops will cause high system pressure, overheating, and damage to the pump and/or gear. 7. Continue draining until all of the old fluid is cleared from the power steering system. Addition of approximately 1 quart of new fluid will be required to flush system. 8. Unplug pump reservoir inlet and reconnect return line. 9. Turn engine off, and fill reservoir to the "Full Cold" mark. 9. Continue with following procedure "Bleeding the Power Steering System". BLEEDING THE POWER STEERING SYSTEM After replacing the fluid or servicing the power steering hydraulic system, you must bleed air from the system. Air in the system prevents an accurate fluid level reading, causes pump cavitation noise and over time could damage the pump. To bleed the power steering system proceed as follows: 1. Begin with the engine off, front wheels off the ground, and wheels turned all the way to the left. 2. Add Low Temperature Climate Service Fluid to the "FULL COLD" mark on the fluid level indicator. 3. Bleed the system by turning the wheels from side to side without hitting stops. IMPORTANT:This may require turning the wheels from side to side several times. Keep the fluid level at the "FULL COLD" mark. Fluid with air in it has a light tan appearance. This air must be eliminated from the fluid before normal steering action can be obtained. 4. Start the engine. With the engine idling, recheck the fluid level. If necessary, add fluid to bring the level to the "FULL COLD" mark. 5. Return the wheels to the center position. Lower front wheels to the ground. Continue running the engine for two or three minutes. 6. Test the vehicle to be sure the steering functions normally and is free from noise. IMPORTANT:Inspect for fluid leakage at connection points along the power steering system. 7. Recheck the fluid level as described in Steps 3 and 4 except that the fluid level should now be up to the "FULL HOT" mark after the system has stabilized at its normal operating temperature. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold Power Steering Fluid: All Technical Service Bulletins P/S - Reduced Assist When Cold Group Ref.: Steering/Suspension Bulletin No.: 033206 Date: March 1994 SUBJECT: REDUCED POWER STEERING ASSIST AT LOW AMBIENT TEMPERATURES (NEW POWER STEERING FLUID) MODELS: 1994 AND PRIOR PASSENGER CARS AND LIGHT DUTY TRUCKS Applications: Appropriate for all passenger vehicles, but particularly beneficial in 1980 and later FWD Models equipped with Power Rack and Pinion Steering. CONDITION: Comments of reduced power steering assist at low ambient temperatures (approximately 10°F and lower) may be noted by some vehicle operators when turning the steering wheel in BOTH the right and left direction during warm-up after cold start. All vehicles with power steering exhibit this condition to varying degrees, but condition may be more noticeable with power rack and pinion steering systems that typically have longer hoses and cooler lines. Note: This condition, which is related to power steering fluid viscosity, should not, however, be confused with conditions having similar symptoms such as that described divisional Special Policy numbers listed: CAUSE: In cold weather, power steering fluid thickens in the same manner as any other petroleum-based oil or fluid. Upon cold starting, the fluid resists movement through the system and the driver senses reduced power assist (sometimes referred to as "stiff steer"). As the vehicle operates and fluid circulates through the power steering system, the fluid warms and thins to its normal operating viscosity. CORRECTION: Saginaw Division has developed a new Low Temperature Climate Service Fluid for use in cold climates. Compared with conventional power steering fluid, this new fluid flows better at low temperatures and resists the thickening which contributes to reduced power assist upon start up. RACK AND PINION STEERING SYSTEMS Reduced power assist upon cold weather starting may be more noticeable in Power Rack and Pinion steering systems that may contain six or more feet of Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold > Page 839 pressure and return hose along with long cooler lines. Such long systems contain greater volumes of fluid and vehicles so equipped tend to have longer periods of reduced power assist. The new fluid performs particularly well with current designed Rack and Pinion steering systems and special remanufactured Rack and Pinion Steering Assemblies. PARTS INFORMATION: Low Temperature Climate Service Fluid is available from GMSPO. Order as: Parts are currently available from GMSPO. SERVICE PROCEDURE: The power steering fluid replacement procedure is a two-stage process: first, flushing the old fluid from the system with new fluid; and second, bleeding the system to remove any trapped air. The two sequences outline the steps in each procedure. FLUSHING THE POWER STEERING SYSTEM 1. Raise the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the fluid return line at the pump reservoir inlet connector. 3. Plug the inlet connector port on the pump reservoir. 4. Position the fluid return line toward a large container in order to catch the draining fluid. 5. While a second person fills the reservoir with new Low Temperature Climate Service Fluid, start and run the engine at idle. 6. Turn the steering wheel from stop to stop. NOTICE: Do not hold the wheel against stops while flushing the system, Holding steering wheel against wheel stops will cause high system pressure, overheating, and damage to the pump and/or gear. 7. Continue draining until all of the old fluid is cleared from the power steering system. Addition of approximately 1 quart of new fluid will be required to flush system. 8. Unplug pump reservoir inlet and reconnect return line. 9. Turn engine off, and fill reservoir to the "Full Cold" mark. 10. Continue with following procedure "Bleeding the Power Steering System". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold > Page 840 BLEEDING THE POWER STEERING SYSTEM After replacing the fluid or servicing the power steering hydraulic system, you must bleed air from the system. Air in the system prevents an accurate fluid level reading, causes pump cavitation noise and over time could damage the pump. To bleed the power steering system proceed as follows: 1. Begin with the engine off, front wheels off the ground, and wheels turned all the way to the left. 2. Add Low Temperature Climate Service Fluid to the "FULL COLD" mark on the fluid level indicator. 3. Bleed the system by turning the wheels from side to side without hitting stops. Important: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold > Page 841 This may require turning the wheels from side to side twenty times. On systems with long return lines or fluid coolers, turning steering wheel lock-to-lock forty times may be required. Keep the fluid level at the "FULL COLD" mark. Fluid with air In it has a light tan appearance. This air must be eliminated from the fluid before normal steering action can be obtained. 4. Start the engine. With the engine idling, recheck the fluid level. If necessary, add fluid to bring the level to the "FULL COLD" mark. 5. Return the wheels to the center position. Lower front wheels to the ground. Continue running the engine for two or three minutes. 6. Test the vehicle to be sure the steering functions normally and is free from noise. Important: Inspect for fluid leakage at connection points along the power steering system. 7. Recheck the fluid level as described in Steps 3 and 4 except that the fluid level should now be up to the "FULL HOT" mark after the system has stabilized at its normal operating temperature. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 912083B > Feb > 91 > Power Steering - Reduced Assist At Low Temperatures Power Steering Fluid: All Technical Service Bulletins Power Steering - Reduced Assist At Low Temperatures Number: 91-208-3B Section: 3B FEBRUARY 1991 Date: Corporate Bulletin No.: 033206R Subject: REDUCED POWER STEERING ASSIST AT LOW AMBIENT TEMPERATURES Model and Year: ALL 1980-91 PASSENGER CARS Applications Appropriate for all passenger vehicles, but particularly beneficial in 1980 and later FWD Models equipped with Power Rack and Pinion Steering. CONDITION Comments of reduced power steering assist at low ambient temperatures (approximately 10 degrees Fahrenheit and lower) may be noted by some vehicle operators when turning the steering wheel in BOTH the right and left direction during warm-up after cold start. All vehicles with power steering exhibit this condition to varying degrees, but condition may be more noticeable with power rack and pinion steering systems that typically have longer hoses and cooler lines. Note: This condition, which is related to power steering fluid viscosity, should not, however, be confused with conditions having similiar symptoms such as that described in divisional bulletins indicated below, related to internal steering gear fluid by-pass. Chevrolet # 88-417-3B CAUSE: In cold weather, power steering fluid thickens in the same manner as any other petroleumbased oil or fluid. Upon cold starting, the fluid resists movement through the system and the driver senses reduced power assist (sometimes referred to as "stiff steer"). As the vehicle operates and fluid circulates through the power steering system, the fluid warms and thins to its normal operating viscosity. CORRECTION: Saginaw Division has developed a new Low Temperature Climate Service Fluid for use in cold climates. Compared with conventional power steering fluid, this new fluid flows better at low temperatures and resists the thickening which contributes to reduced power assist upon start up. RACK AND PINION STEERING SYSTEMS Reduced power assist upon cold weather starting may be more noticeable in Power Rack and Pinion steering systems that may contain six or more feet of pressure and return hose along with long cooler lines. Such long systems contain greater volumes of fluid and vehicles so equipped tend to have longer periods of reduced power assist. The new fluid performs particularly well with current designed Rack and Pinion steering systems and special remanufactured Rack and Pinion Steering Assemblies. PARTS INFORMATION: Low Temperature Climate Service Fluid is available from GMSPO. Order as: Container Size Part Number 16 ounce 12345866 32 ounce 12345867 Parts are currently available from GMSPO. SERVICE PROCEDURE: The power steering fluid replacement procedure is a two-stage process: first, flushing the old fluid from the system with new fluid; and second, bleeding the system to remove any trapped air. The following two sequences outline the steps in each procedure. FLUSHING THE POWER STEERING SYSTEM Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 912083B > Feb > 91 > Power Steering - Reduced Assist At Low Temperatures > Page 846 1. Raise the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the fluid return line at the pump reservoir inlet connector. 3. Plug the inlet connector port on the pump reservoir. 4. Position the fluid return line toward a large container in order to catch the draining fluid. 5. While a second person fills the reservoir with new Low Temperature Climate Service Fluid, start and run the engine at idle. 6. Turn the steering wheel from stop to stop. NOTICE: Do not hold the wheel against stops while flushing the system. Holding steering wheel against wheel stops will cause high system pressure, overheating, and damage to the pump and/or gear. 7. Continue draining until all of the old fluid is cleared from the power steering system. Addition of approximately 1 quart of new fluid will be required to flush system. 8. Unplug pump reservoir inlet and reconnect return line. 9. Turn engine off, and fill reservoir to the "Full Cold" mark. 9. Continue with following procedure "Bleeding the Power Steering System". BLEEDING THE POWER STEERING SYSTEM After replacing the fluid or servicing the power steering hydraulic system, you must bleed air from the system. Air in the system prevents an accurate fluid level reading, causes pump cavitation noise and over time could damage the pump. To bleed the power steering system proceed as follows: 1. Begin with the engine off, front wheels off the ground, and wheels turned all the way to the left. 2. Add Low Temperature Climate Service Fluid to the "FULL COLD" mark on the fluid level indicator. 3. Bleed the system by turning the wheels from side to side without hitting stops. IMPORTANT:This may require turning the wheels from side to side several times. Keep the fluid level at the "FULL COLD" mark. Fluid with air in it has a light tan appearance. This air must be eliminated from the fluid before normal steering action can be obtained. 4. Start the engine. With the engine idling, recheck the fluid level. If necessary, add fluid to bring the level to the "FULL COLD" mark. 5. Return the wheels to the center position. Lower front wheels to the ground. Continue running the engine for two or three minutes. 6. Test the vehicle to be sure the steering functions normally and is free from noise. IMPORTANT:Inspect for fluid leakage at connection points along the power steering system. 7. Recheck the fluid level as described in Steps 3 and 4 except that the fluid level should now be up to the "FULL HOT" mark after the system has stabilized at its normal operating temperature. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Retrofitting R-12 Vehicles to R-134A Refrigerant: Technical Service Bulletins A/C - Retrofitting R-12 Vehicles to R-134A Group Ref.: HVAC Bulletin No.: 331226 Date: January, 1994 INFORMATION SUBJECT: RETROFITTING R-12 VEHICLES TO R-134a MODELS: 1994 AND PRIOR YEARS, PASSENGER CARS AND TRUCKS WITH R-12 A/C SYSTEMS There has been a great deal of information presented by the media regarding the need to retrofit vehicles produced with R-12, to a substitute refrigerant. This bulletin will outline GM's position and future plans on this subject. Most important, there is currently NO requirement to retrofit any R-12 vehicle. Vehicles built with R-12 can be serviced with R-12, as long as the refrigerant is available. At some point in time, R-12 may become either too scarce or too expensive to economically justify service on some vehicles with R-12. By that time, GM will provide you with instructions on retrofitting those vehicles from R-12 to R-134a. GM vehicle divisions, platforms, and component suppliers have been actively working on the details of retrofitting R-12 vehicles. An enormous amount of work is required to determine how hundreds of vehicle models can be satisfactorily retrofitted. Additional information will be provided as it becomes available. The following items contain important technical information that should answer many of the questions, and correct some misconceptions reported in the media. SUBSTITUTE REFRIGERANTS R-134a is the only approved substitute refrigerant that GM recommends and it should only be used if a complete retrofit procedure has been performed. None of the other refrigerants currently being marketed as replacement or drop-in substitutes for R-12 are approved for use in GM vehicles. R-12 and R-134a are not interchangeable. R-134a cannot be added to fill a low R-12 system. The combination of the two materials can cause high system pressures, which could cause damage to the system. Retrofitting an R-12 vehicle to R-134a requires careful preparation to insure that neither the vehicle nor the A/C service equipment has become contaminated. RESIDUAL MINERAL OIL The concern that mineral oil is chemically incompatible with R-134a and/or PAG lubricant has been proven to be untrue. A normal charge of mineral oil left in the A/C system after a retrofit to R-134a will not damage the system. Mineral oil, however, does not mix well with R-134a, and will not provide adequate lubrication. Tests on both the orifice tube and TXV systems show that the mineral oil parks in places such as the accumulator, and does not appreciably affect performance or damage the system. The retrofit service bulletin will specify the correct oil to be used. It is important that this oil recommendation be followed carefully. RESIDUAL R-12 Residual R-12 left in a system, due to improper retrofit service procedures, may result in system damage unless the residual R-12 is kept below the 2 percent limit specified by the Society of Automotive Engineers' Specification J-1661. New service methods are being developed to minimize the level of R-12 remaining in the A/C system after the retrofit procedure is completed. Following these new procedures will be critical to insure that the above limits are met. SYSTEM FLUSHING R-11, a material commonly used as an A/C system flushing solvent, has been found to be chemically incompatible with PAG lubricant. Technicians should be aware that residual R-11 remaining in an R-12 system will be very damaging if the vehicle is retrofitted to R-134a later in its life. For many years GM has recommended the use of in-line filters as an alternative to system flushing. SYSTEM FLUSHING, USING EITHER R-11 OR ANY OTHER FLUSHING MATERIAL, IS NOT APPROVED BY GM FOR ANY A/C SYSTEM. DESICCANT PROTECTION Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Retrofitting R-12 Vehicles to R-134A > Page 851 It has been reported that the desiccant (moisture absorption material) used in 1992 and older R-12 A/C systems is incompatible with R-134a and PAG oil. The older desiccant was designed specifically for R-12 systems, but testing has shown that it is NOT necessary to replace the older desiccant just because the vehicle is being retrofitted to R-134a. 1993 and newer GM vehicles use desiccant designed to be compatible with both R-12 and R-134a systems. The amount of desiccant used in most GM vehicles is designed to last for at least seven years. To help maintain adequate protection for vehicles that must be retrofitted, it is recommended that the accumulator/dryer, which contains the desiccant, be replaced if the vehicle is more than five years old. "O" RINGS While continuing to service with R-12, be sure to use "O" rings and seal materials which are compatible with R-134a and PAG oil. This practice will eliminate concern in case the vehicle requires retrofitting later in its life. All "O" rings and seal materials available from GMSPO are compatible with R-134a systems. RETROFITTED SYSTEM PERFORMANCE Currently, it appears that for most GM vehicles, the retrofit procedure will require minimal changes to the existing system. Some vehicles may need additional parts and/or procedures to provide acceptable performance and/or durability. Our testing has shown that vehicles that have undergone recommended retrofit procedures will, in most climatic conditions, be minimally affected in terms of A/C performance. SERVICE POLICY Basic service policy is as follows: During Warranty - If an R-12 produced vehicle A/C system must be repaired or recharged under warranty, repairs will be completed using R-12. If R-12 is unavailable or unaffordable, GM will notify the dealer body and will pay for the warranty repair and the retrofit to R-134a. NOTE: It a customer requests that an in-warranty vehicle be converted to R-134a, and the R-12 system is functioning properly, the customer will be expected to pay for the retrofit. Out of Warranty - The cost of the conversion will be the responsibility of the customer. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a Technical Service Bulletin # 431207E Date: 970101 A/C - Retrofitting R-12 to R-134a File In Section: 1 - HVAC Bulletin No.: 43-12-07E Date: January, 1997 INFORMATION Subject: Guidelines for Retrofitting R-12 Vehicles to R-134a Models: 1984-94 Passenger Cars and Trucks (See List Below) This bulletin is being revised with the following changes: 1. Addition of all remaining GM vehicles, as listed. 2. Format rearranged for easier use. Please discard Corporate Bulletin Number 43-12-07D (Section 1 - HVAC). Car/Truck Platform Coverage Starts: 1984 - A, B, D, E, F, J, K, P, Y Carlines 1985 - C, M, N, R, S Carlines 1986 - H Carline 1987 - L, V (Allante) Car lines; M/L, G, R/V, S/T, P Truck lines 1988 - T (LeMans), E (Reatta), W Car lines; C/k, MED. Duty Truck lines 1989 - Tracker 1990 - U Van Vehicles Not Covered: T (Chevette and T1000), G RWD, C RWD, and X Car If a vehicle is not covered in the list above, GM's recommendation is that the vehicle continue to be serviced with R-12. This bulletin outlines the detailed retrofit procedures, as well as providing background information on many components and procedures. It is important to follow the bulletin, since each car and truck line has unique parts and procedures. However, the basic procedure is simple, and will become easier as you complete more retrofits. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 857 Retrofit Requirements The customer should be reminded that there is NO requirement in the U.S. to retrofit any vehicle produced with R-12. Vehicles built with R-12 can be serviced with R-12 as long as it is available (except in certain Canadian Provinces). GM has taken steps to extend the supply of R-12 and recommends that all R-12 vehicles continue to be serviced with R-12 as long as it is available. Training Video Before doing a retrofit the first time, it is recommended that you view the Certified Plus Training Video, Program number 51010.15, "R-134a Retrofit for GM Cars and Trucks". Table of Contents A. Retrofit Procedure 1. Inspect Condition of Vehicle 2. Recover the R-12 (new method) 3. Install the service port conversion fittings 4. Install any additional parts needed 5. Evacuate and recharge with new PAG or V5 retrofit oil and R-134a 6. Install the retrofit label Platform Details Compressor Replacement Chart B. General Information 1. Performance 2. Leakage 3. Desiccant 4. Improved Cooling Performance 5. PAG or V5 Oil Compatibility 6. Refrigerant Oil Level Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 858 C. Parts Information D. Warranty Information 1. Vehicle Still in Warranty 2. Customer Paid' Retrofitting Costs 3. Labor Time Information Notes on Retrofit Important: Before proceeding with any retrofit, make sure you have all component Parts required on hand to perform a proper and complete repair with Minimal downtime. R-12 Removal Prior to Retrofit To prepare a system for retrofitting, the R-12 must be recovered and the system must be completely evacuated. Evacuation is necessary to insure that small amounts of R-12 and air remaining in the system are removed. This will prevent cross contamination of the two refrigerants, which could lead to reduced A/C system reliability and performance. It is very important that the specified times for waiting after recovery and evacuation not be reduced. This time is required to sufficiently remove residual R-12 from the oil in the system. A considerable amount of testing has determined that the following procedure is required to achieve satisfactory results and conform to SAE J 1661: 1. Inspect Condition of Vehicle Install the gauge set on the high and low side ports. Use normal diagnostic procedures to find the cause of the vehicle's reported condition. One of three conditions will exist with the refrigerant system: a. System pressure correct, no leaks - proceed to Step 2 (Recovery). This would normally apply when: 1. The system must be recovered/recharged for a repair to a system other than the A/C system, or 2. Where the A/C system condition did not involve leaks, but requires recovery/recharge to replace a component. b. Compressor not operating, but some charge. Leak test to find the leak, complete Step 2 (Recovery), then correct the leak before proceeding with Step 3 (Conversion port installation). c. No charge in system - proceed with the Conversion port installation in Step 3. Use the ACR4 to evacuate for 5 minutes. If the leak can be heard, repair the leak. If the leak cannot be heard, charge with 1/2 pound of R-134a. Leak test with the J 39400 Leak Detector, recover the R-134a, repair any additional leaks found, and proceed with the evacuation in Step 5. 2. Recover the R-12 from the System Notice: THIS PROCEDURE IS DIFFERENT THAN THE NORMAL (NON-RETROFIT) RECOVERY PROCEDURE. R-12 will be recovered through the HIGH SIDE SERVICE PORT ONLY, WITH THE ENGINE RUNNING. Recovery through the low side will not effectively remove the R-12 from the accumulator, resulting in possible damage to the retrofitted system. Important: Vehicle must be above 50° F (10° C) to allow for complete recovery of the R-12. If it is not, either allow it to warm up in the shop overnight, or increase the evacuation time in Step 5.a to 30 minutes. a. Connect the recovery hose from the R-12 recovery cart (ACR3) to the middle port of the A/C gauge set. Open the oil drain valve on the ACR3 cart long enough to drain the oil. Failure to do so could cause excessive amounts of oil to build up in the separator, resulting in damage to the recovery cart compressor. b. Start the engine. Leave the hood up, and the windows open. On vehicles with manual A/C controls, set the A/C controls to normal A/C mode, high blower, and temperature control to full cold. On cars with automatic A/C controls, set the temperature to 75° F, "AUTO" mode, and manually select high blower. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 859 Make sure the vehicle compressor is engaged. Turn the cart on and start the recovery cycle. OPEN ONLY THE HIGH SIDE VALVE ON THE GAUGE SET. The vehicle system should eventually shut the compressor off. If the low side pressure drops below 15 psi, and the compressor does not turn off, turn it off now (go to "VENT" or "ECON" mode), but leave the engine running and the blower on "high". c. After the recovery cart shuts off the first time, wait 5 minutes. If the pressure on either the high or the low side rises above 0 psi, restart the recovery process. After the second shutoff, wait 2 minutes. If the pressure again rises above 0 psi, restart, and after shutoff, again wait 2 minutes. The process can be stopped when the pressure does not rise above 0 psi after 2 minutes. The engine can be shut off at this time. d. Remove the R-12 reclaim hose and the gauge set from the vehicle. Any repairs needed should be done at this time. If any components other than the compressor are replaced, they should be installed dry, and no extra oil should be added. 3. Install the Service Port Conversion Fittings Important: For GEO vehicles, skip to Step 4. Fitting installation is covered in that step. For vehicles that require a HPCOS, see Step 4. Some of these vehicles use a specific combination fitting to mount the HPCOS, which includes the high side service port fitting and the HPCOS port. The low side fitting is installed as detailed below. See "Platform Details" for further information. Important: A new tool kit, P/N J 39500-250, has been released. This kit contains the following items: ^ J 39500-71 Oil Injection Bottle Conversion Kit (includes 3 12 oz bottles, an extender tube, caps, and fittings) ^ J 39500-275 Tool kit, including the following: (See Figure 2) - J 34611-A Double ended valve core remover - J 25498-A High side adapter fitting - J 38702 Deep valve core adapter fitting Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 860 - J 41265 Thread cleaning wire brush - J 41266 Low side port thread restorer - J 41267 High side port thread restorer - J 39037 High side octagon socket - J 41256 Low side octagon socket New low profile, quick connect couplers, J 39500-20A (High side), and J 39500-24A (Low side), have been released as essential tools, to attach to the ACR4 (see Figure 3). These are much smaller couplers than the existing ones, and will allow attachment to the port fittings in much tighter quarters. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 861 Select and install the proper R-134a fittings (shown in Figure 4) from the chart below, based on how the ACR4 couplers will attach. Also, remember to check for proper hood clearance with the conversion fittings. Try the straight fittings first. The two-piece high side fitting is used when the existing fitting is screwed into the pipe fitting (some 1992, and nearly all 1993 models, use these fittings). Use the 90° elbow if the straight fitting does not allow the ACR4 couplers to connect. Fitting Type High Side Low Side Straight 52467941 52467943 Straight Two-piece 52467324 N/A 90° Elbow 52469054 52469055 The fittings should be installed as follows: a. Remove the caps from the R-12 fittings. Remove any dirt or grease from the port threads using the thread cleaning wire brush, J 41265. Inspect the fittings for thread damage. If any damage is found, use the port thread restorer (J 41266 low side, J 41267 high side) to repair the thread. For the two-piece fitting, remove the existing R-12 fitting and discard it. Use tool J 38704A (previously released, not part of the above kit) to remove the fitting. Make sure to hold the line securely to prevent damage when removing the existing fitting. If the fitting cannot be removed easily, use the saddle clamp valve listed below and seal the R-12 port and cap permanently. b. Install the selected fitting onto the existing R-12 fitting. Leave the valve core in the straight fittings, and remove the valve core when using the 90° fittings. If the valve cores need to be removed at a later time, they can be removed with the straight conversion fittings in place. On the low side straight fitting, use the J 34611-A tool to remove the core pin in the conversion fitting, then remove the core valve from the original R-12 fitting. Always recover the charge before valve core removal. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 862 Use the octagon sockets on the straight fittings (J 39037 high side, and J 41256 low side). Torque the new fitting until it seats. The fitting should seat fully BEFORE reaching 11 N.m (8 lb ft). If 11 N.m (8 lb ft) of torque is reached and the fitting has not seated, it is probable that the threads have been damaged. In this case, remove the fitting and use the thread restorer listed above. Reinstall the fitting, adding one drop of a thread locking compound such as Loctite(R) 242. The fittings (except the two-piece) have a thread locking compound applied to the threads. This compound will set up enough to restrict removal of the fitting in about 15 minutes. The fittings can now be used to evacuate the system (see Step 5). An additional type of conversion port fitting has been developed. This fitting is called a saddle clamp valve (see Figure 5). It can be clamped directly on a metal refrigerant line, and will be used if the existing fitting is damaged or is inaccessible. A drop of a thread locking compound, such as Loctite(R) 242, should be used on each bolt to prevent the threads from loosening. The R134a saddle clamp valve part numbers are: If an existing R-12 service port is not used, it must be rendered inoperative. Place several drops of a thread locking compound, such as Loctite(R) 243, in the valve core, and onto the cap threads. Secure the cap and let it set for 15 minutes. 4. Install Any Additional Parts Needed See "Platform Details" after Step 6. If a vehicle is listed as a "Basic Retrofit", no additional parts are required (except for compressors, see the Compressor Replacement Chart at the beginning of Platform Details). If no parts are required, PROCEED TO STEP 5. Compressors Compressors do not need to be replaced as part of a normal retrofit, unless indicated in the Compressor Replacement Chart. An R-12 compressor that is operating properly can, in most cases, be left in the vehicle when it is retrofitted to R134a. However, if a compressor failure is the reason the vehicle is in for service, and the vehicle will be retrofitted, OR if a vehicle has already been retrofitted with R-134a and the compressor fails at some time in the future, new compressors for use with R-134a are available. See the GMSPO Parts Catalog for specific part numbers. DO NOT use a replacement R-12 compressor for any vehicle retrofitted to R-134a (unless it is the new "oil-less" design). See "Compressor Availability" at the end of the Compressor Replacement Chart. Accumulator /Dryer If the vehicle is more than 5 years old, the Accumulator/Dryer (A/D) should be replaced to ensure that moisture is removed from the system. See the instructions for proper A/D identification in General Information. High Pressure Cut-Off Switch (HPCOS) Most trucks, and some 1984-93 B and D cars, require that a HPCOS be added to protect the refrigerant system during long idles at high temperature. The HPCOS kit (P/N 15981985) contains the switch, wire harness, heat sealing splice connectors, switch "0" ring, and installation instructions. A saddle clamp adapter (P/N 15985307), or a special dual fitting, is mounted to the high pressure line, and provides the port to mount the switch. A drop of a Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 863 thread locking compound, such as Loctite(R) 242, should be used on each bolt of the saddle clamp to prevent the threads from loosening. Some vehicles produced during the second half of the 1993 model year will already have a factory installed HPCOS. Check the back of the compressor for this switch. If present, the above switch will not have to be added. 5. Evacuate the System, and Recharge with PAG or V5 Retrofit Oil and R-134a Newly designed low profile quick connect couplers for the ACR4, J 39500-20A and J 39500-24A, have been released. These should be installed before proceeding with the evacuation. See Step 3, and Figure 3. a. Connect the R-134a cart (ACR4) to the system. Open the coupler valves on the hoses so that the pressures can be read on the gauges. On the cart, open the HIGH SIDE VALVE ONLY. DO NOT OPEN THE LOW SIDE VALVE! Program the cart for a 15 minute evacuation. Important: If the vehicle has been at outside temperatures of less than 50° F (10° C), or at high altitudes (above 3000 ft), use a 30 minute evacuation to insure complete removal of the R-12. If the vacuum pump will not start and a "H-P" reading is indicated on the ACR4 display, loosen the fitting at the high side line connection to the ACR4 to relieve pressure in the line. Tighten the fitting after pressure has been relieved. DO NOT USE THE RECOVERY MODE TO RELIEVE LINE PRESSURE. b. Start the evacuation. For a proper evacuation, the cart must pull down to 28-29 in. Hg. at sea level (reduce by 1 in. for each 1000 ft above sea level). Check the low side gauge for proper vacuum level, to make sure the new fittings are operating properly. While the evacuation is being done, the Retrofit label can be filled out and installed (see Step 6). Important: If the compressor was replaced at the same time as this retrofit, and the new compressor was shipped with the correct amount of PAG oil already in it, DO NOT add any additional oil to the system! Go to Step D. If an "oil-less" compressor was installed, add oil in Step C. A new retrofit oil for use with V5 compressor vehicles has been released. This oil will be used ONLY for retrofitted vehicles in which the original V5 compressor is retained. IT WILL NOT BE USED IF A COMPRESSOR IS REPLACED AT THE TIME OF THE RETROFIT. Failure to use this oil may significantly shorten the useful life of the compressor. Important: If the V5 Retrofit oil is not available from GMSPO, the compressor MUST BE REPLACED! To summarize the correct retrofit oil usage: ^ Compressor replaced during retrofit - NO OIL ADDED if new compressor shipped with oil - 8 oz. of PAG oil (9 oz of PAG oil with V5 compressor) added if compressor shipped without oil ("oil-less" design) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 864 ^ PAG oil used for future service if needed (mark PAG on box on label, Figure 6). ^ HR6 or R4 original compressor RETAINED - add 8 oz FAG oil to system ^ V5 original compressor RETAINED - add 9 oz V5 Retrofit oil to system. If V5 Retrofit oil is not available from GMSPO, REPLACE THE COMPRESSOR. c. Based on the above chart, add oil if needed. Use the new oil bottle and the extended tube kit, J 39500-71. Fill the bottle with at least 10 oz of oil. Attach the new bottle to the back of the ACR4, and open the oil fill valve. Allow the correct amount of oil to be drawn into the system. DO NOT allow the oil level to drop below the end of the pickup tube. This will prevent any air from being drawn into the system. If any oil was removed during the R-12 recovery evacuation steps, DO NOT add additional oil to replace it. d. Determine the correct amount of R-134a to use. Check the existing label of the vehicle for the R-12 charge amount. Use the formula {(R12 x .9) - .25 lb = R-134a} to determine the correct charge. This can also be stated as: Take 90% of the R12 charge, and subtract 1/4 lb. Follow the directions for the ACR4 cart to recharge the system. At the end of the process, "CPL" will be displayed. Close the high side valve. e. Start the vehicle, turn on the A/C system, and confirm that pressures are within normal operating ranges, as shown in the 1994 Service Manual. The 1994 Service Manuals can be used as a reference for diagnosis and specification of retrofitted systems. On some vehicles with automatic A/C controls or low charge diagnostics, the A/C compressor may not engage if any diagnostic codes were set during the retrofit. Check to see if any codes were set in either the HVAC or Engine Control systems. If they were, clear the codes following the directions in the Service Manual. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 865 f. TO INSURE AN ACCURATE CHARGE AMOUNT, IT IS IMPORTANT TO CLEAR THE ACR4 OF ANY REMAINING REFRIGERANT. Close the high side coupler valve and remove the high side hose from the vehicle. Then, open both the high and low side valves on the ACR4. After the pressures on both gages are at low side pressure, close the low side coupler valve. See Step G below, then remove the low side hose from the vehicle. Shut off the engine. Install the service port caps on the new fittings. These serve as a seal and can prevent system leaks. g. In the unlikely event that the low side fitting leaks when the coupler is removed, use the following procedure: 1. Immediately reinstall the coupler on the fitting. 2. Find the valve core remover J 34611-A. 3. Remove the coupler. 4. Use the double-ended valve core remover to turn the valve core pin counter-clockwise until the leak stops. 5. Install the cap. If the leak was substantial or continued for an extended period of time, it is highly recommended to evacuate and recharge the system to insure proper performance. If there is any question, the system can be rechecked by repeating Step F. h. Leak test any new port fittings, adapters, or valves that were installed, and any joints that were opened or repaired during the retrofit process, using tool J 39400. 6. Install the Retrofit Label The retrofit label (P/N 21030857, roll of 250) has been developed following SAF specifications to insure a smooth transition from R-12 to R-134a, and to insure a professional approach to the retrofit and a quality repair. Following the instructions in this bulletin will insure that the retrofit meets the SAE standards. Fill in the new label using a typewriter or a ball-point pen (see Figure 6). Select a location for the label that will be easily visible. Some suggested areas are the radiator support panel, an area near the existing R-12 charge label, or a flat surface near the high or low side service ports. The area selected should be a clean, underhood, painted sheet metal surface, and should be degreased and wiped down with a non-petroleum based cleaner. Do not install the label on a rubber surface. Apply the label, then apply the clear overlay to the label. Do not remove, cover, or render unreadable the existing R-12 charge label. DO cover the R-12 refrigerant charge amount on the existing label with an indelible, preferably black, marker. Platform Details Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 866 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 867 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 868 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 869 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 870 FOR ALL VEHICLES EXCEPT GEO, see the "Compressor Replacement Chart" at the end of this section. Compressor replacement requirements ARE NOT LISTED in the platform details (except for application details), except as noted below for Y car and P and Medium Duty truck. Compressor Replacement Chart Important: It is important to check the date code on the compressor. Any vehicle may have had a compressor replaced either during or after the warranty period. The date code will determine whether or not the compressor must be replaced. Compressor Availability A new compressor for use with R-134a systems will be shipped with the correct amount of PAG oil installed (see "IMPORTANT" below). Do not add any additional oil in Step 5 of the retrofit procedure if a compressor is to be replaced with a new R-134a compressor at the same time the initial retrofit is Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 871 being done. Important: During 1996, "oil-less" compressors began to be serviced with NO added oil. New part numbers will be issued, and both the box and the compressor will be clearly marked to indicate that no oil is present. If you receive one of these newer compressors, simply add the normal amount of oil to the system in Step 5 of the retrofit procedure (8 oz of PAG oil, or 9 oz of PAG oil with V5 compressor). These "oil-less" compressors are compatible with EITHER R12 or R-134a. Geo Models Compressors DO NOT HAVE TO BE REPLACED as part of the retrofit. New compressors are shipped with enough oil to accommodate the entire A/C system. Do not add additional PAG oil to the system it the compressor is being replaced. 1985-88 Nova, 1989-93 Prizm (S) 1. Using the Service Manual, remove the following components in the order given: a. Receiver/dryer. b. Loosen evaporator to compressor (suction) pipe (to be reinstalled) c. 1985-92 only: Loosen compressor to condenser (compressor discharge) pipe (to be reinstalled). d. 1985-88 only: Service Valve & Extension Housing on compressor (to be installed). e. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High and low side adapter fittings (see Step 3 of the retrofit procedure for detailed installation instructions). c. 1985-88 only: Service Valve & Extension Housing on compressor using new 0-rings. Six small 0-rings and one large 0-ring are required. d. Evaporator to compressor (suction) pipe 0-ring. e. 1985-92 Compressor to condenser (discharge) hose 0-ring. f. Receiver/dryer and 0-rings. R-134a amount: 85-92 - 650 grams (1.43 lb) 93 - 700 grams (1.54 lb) PAG oil amount: 100 cc (3.0 oz) Parts Required: Receiver/dryer: 85-88 - 94855761 89-93 - 94855762 Adapter Fittings: Low Side - 94855760 High Side - 94855759 0-Rings: 85-88 Compressor - Small 0-rings (6 required) - 94857336 - Large 0-ring - 94857337 85-93 Receiver/Dryer (2) - 94845949 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 872 85-93 Suction hose - 94855765 85-92 Discharge hose - 94845943 1985-88 Sprint, 1989-93 Metro (M) 1. Using the Service Manual, remove the following components in the order given: a. Receiver/dryer. b. Evaporator to compressor (suction) pipe. c. Compressor to condenser (compressor discharge) pipe. d. Joint service connector on compressor (to be reinstalled). e. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High and low side adapter fittings (see Step 3 of the retrofit procedure for detailed installation instructions). c. Joint service connector to compressor. Use new 0-rings. Six small 0-rings and one large 0-ring are required. d. Evaporator to compressor (suction) pipe, and new 0-ring. e. Compressor to condenser (discharge) hose and new 0-ring. f. Receiver/dryer and 0-ring. R-134a amount: 500 grams (1.10 lb) PAG oil amount: 100 cc (3.0 oz) Parts Required: Receiver/dryer: 85-86 - 91172081 87-88 - 91172079 89-93 - 96068480 Adapter Fittings: Low Side - 91172092 85-88 - High Side - 91172094 89-93 - High Side - 52467941 0-Rings: Compressor - Small 0-rings (6 required) - 91172095 - Large 0-ring - 96068915 Receiver/Dryer (2) - 96068488 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 873 89-93 - Suction hose - 96068490 89-93 - Discharge hose - 96068489 Suction hose: 85-86 - 91172086 85-86 Dealer installed: 91172087 87-88 - 91172088 89-93 - w/turbo - 96069121 - w/o turbo - 91172089 Discharge hose: 85-86 - 91172082 85-86 Dealer installed: 91172083 87-88 - 91172084 89-93 - 96069024 1989-93 Tracker 1. Using the Service Manual, remove the following components in the order given: a. Receiver/dryer. b. Evaporator to compressor (suction) pipe. c. Compressor to condenser (compressor discharge) pipe. d. Joint service connector on compressor (to be reinstalled). e. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High and low side adapter fittings (see Step 3 of the Retrofit procedure for detailed installation instructions). c. Joint service connector to compressor. Use new 0-rings. Six small 0-rings and one large 0-ring are required. d. Evaporator to compressor (suction) pipe, and new 0-ring. e. Compressor to condenser (discharge) hose and new 0-ring. f. Receiver/dryer and 0-ring. R-134a amount: 550 grams (1.21 lb) PAG oil amount: 100 cc (3.0 oz) Parts Required: Receiver/dryer - 91172080 Adapter, Low Side - 91172092 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 874 Adapter, High Side - 91172093 0-Rings: Compressor - Small (6) - 91172095 Large - 96068915 Receiver/dryer (2) - 96068488 Suction hose - 96068490 Discharge hose - 96068489 Suction hose - 91172091 Discharge hose - 91172085 1985-89 Spectrum and 1990-93 Storm (R) 1. Using the Service Manual, remove the following components in the order given: a. Condenser (Storm) or radiator grille (Spectrum) (to be reinstalled). b. Triple switch (Storm) or dual pressure switch (Spectrum) (to be reinstalled). c. Receiver/dryer. d. Evaporator to compressor (suction) pipe. e. Check valve from high side service valve (discard). f. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High side adapter fitting (see Step 3 of the retrofit procedure for detailed installation instructions). Low Side - Part of suction hose c. Evaporator to compressor (suction) pipe, and new 0-rings. d. Receiver/dryer and 0-rings. e. Triple switch or dual switch, and new 0-ring. f. Condenser or radiator grille. R-134a amount: 91 - 500 grams (1.10 lb) 92-93 - 600 grams (1.32 lb) PAG oil amount: 150 cc (4.50 oz) Parts Required: Receiver/dryer: 85-89 - 97104795 90-91 - 97104797 92-93 - 97104798 Adapter, High Side: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 875 85-89 - 97104794 90-93 - 97104793 Adapter, Low Side: Part of Hose Asm. 0-rings: Receiver/dryer 85-91 - 94154048 92-93 - 94461700 Switch/pipe - 94461902 Suction hose: 85-86: 1.5L - 97104799; 1.6L - 97104800 90-93: 1.6L - 97104801; 1.8L - 97104803 B. General Information Several items affecting the performance and durability of the system should be considered: 1. Performance When performed properly, the retrofit from R-12 to R-134a will have minimal effect on the system's performance in most climatic conditions found in the United States and Canada. 2. Leakage Experience has shown that most leakage in an A/C system is due to leaks at the joints, or through a small leak in a hose, usually at the coupling. The R-134a molecules are smaller than R-12, and a small leak may result in a faster loss of refrigerant with R-134a. Because of this, it is very important to leak check all vehicles using the J 39400 leak detector, BEFORE the retrofit is performed, and repair any leaks found. "0" rings and hoses used in most GM vehicles are compatible with R-134a and do not need replacement during a retrofit. "0" rings or hoses installed in previous repairs may have been of non-compatible materials if GM parts were not used and will be more likely to deteriorate and leak than the original equipment materials. All "0" rings and hoses available through GMSP0 are compatible with R-134a. Remember that the normal policy is to replace the "0" rings whenever a joint is opened for any reason. 3. Desiccant You may have heard that the currently used desiccant in the accumulator is not compatible with R-134a. Extensive testing has shown that it is, in fact, suitable for use with R-134a, once it has been in service in an R-12 system. The accumulator in these models will not have to be changed during the retrofit procedure, unless the vehicle is more than 5 years old. Vehicles more than 5 years old should have the A/D replaced to add new desiccant for proper system drying. In the event that an accumulator/dryer (A/D) needs to be replaced on a retrofitted system in the future, only A/D's with XH-7 desiccant should be used. The service parts for the 1993 vehicles contain only XH-7 desiccant. The parts for the 1992 and older vehicles may contain either XH-5 or XH-7. Parts containing XH-7 can be identified (see Figure 1) by 1) an "A" printed on the top of the A/D; or 2) if there is a label on top of the A/D, there will be a square with an "A" inside; or 3) if there is a time code and date printed on top of the A/D just under the "Harrison" logo, the A/D contains XH-7. A/D's containing XH-5 can still be used on R-12 vehicles. 4. Improved Cooling Performance There have been service bulletins issued in the past with information improving the cooling performance of existing R-12 systems. These bulletins can also be used to improve the performance of retrofitted vehicles in high ambient temperature climates. 5. PAG or V5 Oil Compatibility Contrary to information published to date outside of General Motors, mineral oil and PAG or V5 oil ARE chemically compatible. The mineral oil left in the system after reclaiming the R-12 can remain in the system with no harmful effects. However, the mineral oil will not mix with the R-134a, and so will not circulate and perform its lubricating function. Testing has shown that most of the mineral oil will eventually collect in the Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 876 accumulator. The system will operate properly as long as refrigerant charge amounts are strictly adhered to. 6. Refrigerant Charge Level The retrofit R-134a charge level is more critical than with R-12 systems. Overcharging may push the mineral oil out of the AID, and cause it to circulate as a liquid. This is more likely to result in compressor damage. Undercharging may lead to loss of performance. It is very important to clear the hoses during the charging operation, to insure that all the refrigerant is delivered to the vehicle A/C system. This is covered in Step 6D of the Retrofit Procedure. C. Parts Information Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 877 Important: All of the following parts are NOT NEEDED for a normal retrofit. Follow the bulletin procedures to determine which parts you need! Individual vehicle kits are not necessary, since most of the parts are generic and only a few parts are needed for most vehicles. GEO Parts are listed in "Platform Details." Parts are currently available from GMSPO. D. Warranty Information 1. Vehicle Still Within the Original New Vehicle Limited Warranty Period When GM models for the years listed in the bulletin require repairs to the refrigerant system and the vehicles are still covered under the New Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 878 Vehicle Limited Warranty, dealers are instructed to proceed as follows: Important: On vehicles equipped with A/C systems NOT produced by GM (i.e., rear A/C systems in van conversions), consult the manufacturer of that A/C system for retrofit guidelines. ^ Offer the customer the option of repairing and recharging the system with R12, or retrofitting after repair and recharging with R-134a at no additional charge. ^ Provide the owner with, and review the information contained in, the "Converting Your Auto Air Conditioning System to Use the New Refrigerant" brochure. (Brochure, Form GM-0011, can be ordered free of charge from GM Fulfillment HQ, Phone 1-800-269-5100). ^ Record the customer's choice on the repair order and, as with all properly completed repair orders, ask the customer to sign on the appropriate line acknowledging the repairs requested. ^ Under no circumstances should the retrofit to R-134a be performed unless the customer has had the option explained prior to repair. Once the vehicle has been retrofitted to R-134a, a significant expenditure would be incurred to go back to R-12, in the event the customer has changed his/her mind. THIS OFFER APPLIES ONLY TO VEHICLES REQUIRING A/C REFRIGERANT SYSTEM REPAIRS UNDER THE TERMS OF THE NEW VEHICLE LIMITED WARRANTY. It is not a special policy, and any existing deductibles still apply. This is simply an option being offered to the customer during the warranty period at this time. GM reserves the right to terminate this offer at any time. If the R-12 refrigerant system does not require discharging for a warranty repair, but the customer requests a retrofit to R-134a, the retrofit WOULD BE PERFORMED AT THE CUSTOMER'S EXPENSE, EVEN DURING THE WARRANTY PERIOD. 2. Customer Paid Retrofitting Costs If the customer requests a retrofit to R-134a, for a specific vehicle whose retrofit parts and procedures have been released in this bulletin, the customer would be expected to pay the costs to retrofit under the following conditions: ^ The vehicle is no longer covered by the terms of the New Vehicle Limited Warranty. ^ The vehicle is covered by warranty, but the repair covered under the warranty does not require evacuating and recharging the refrigerant system. 3. Labor Time Information For Vehicles Repaired Under Warranty: Use existing labor operations for correcting the original condition. The quantity of R-134a used should be charged to the normal labor operation (not D4500), just as if it were R-12. Use D4500, 0.3 HR., to charge for parts and labor, for all of the following items: ^ Additional time for recovery of R-12 to meet SAE standards; ^ Install high and low side service port converter fittings; ^ Add PAG or V5 retrofit oil; ^ Complete label information and install. Add 0.2 hours to D4500 for installation of the HPCOS. Use T5321, 0.3 HR., for the Pontiac Bonneville hood seal installation. ANY PARTS OR LABOR TIME OTHER THAN THOSE LISTED ABOVE SHOULD BE CHARGED TO THE REGULAR LABOR OPERATION CORRESPONDING TO THE ORIGINAL CONDITION THAT 1S BEING REPAIRED. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 631209 > May > 96 > A/C - R12 or R134a Service Recommendations Technical Service Bulletin # 631209 Date: 960501 A/C - R12 or R134a Service Recommendations File In Section: 1 - HVAC Bulletin No.: 63-12-09 Date: May, 1996 INFORMATION Subject: Service Issues for Vehicles with R12 or R134a Air Conditioning Systems Models: 1988-96 Passenger Cars and Trucks R12 Service Recommendations As you know, production of R12 refrigerant ceased on December 31, 1995. Although R12 will no longer be manufactured, there is a reserve supply of R12 available. This reserve, along with strict A/C repair service adherence to proper refrigerant recycling procedures, should assure continued availability to meet consumers' needs. R12 can and should continue to be used to service vehicles built with R12 A/C systems as long as it is available. If R12 is no longer available or affordable, a system retrofit utilizing R134a is recommended. R134a IS THE ONLY SUBSTITUTE REFRIGERANT RECOMMENDED BY GM FOR USE IN GM VEHICLE A/C SYSTEMS, AND THEN ONLY AFTER FOLLOWING THE PROPER RETROFIT PROCEDURES FOR THE SPECIFIC MODEL. All new vehicle manufacturers have chosen R134a for retrofit. One of the key reasons is to protect both the service industry and consumers from the high costs that would result from purchasing equipment necessary to service multiple refrigerants. This position also reduces the threat of recycled refrigerant contamination. GM currently offers a simple, low cost R12 to R134a retrofit on many of its late model, front wheel drive passenger cars. Dealers should discuss this capability with owners of these specific models, listed in Retrofit Corporate Bulletin # 43-12-07D, whenever a repair to the A/C refrigerant system is required. Early retrofit of these specific models will aid in prolonging availability of the R12 supply and provide dealer service technicians the opportunity to become more familiar with the proper procedures for performing a retrofit. Remember - R12 and R134a refrigerant are not interchangeable! They cannot be mixed together. In fact, despite the claims of some refrigerant manufacturers, no proposed R12 refrigerant substitute can be added to, mixed with or used to "top off" an R12 system. Under provisions of law covering the service of refrigerants, mixing dissimilar refrigerant products during service is prohibited. To Summarize GM R12 Service Policy 1. Service R12 vehicles with good quality new or recycled R12 as long as it is available. 2. Purchase R12 from a reliable supplier. GMSPO has a supply of high quality R12 available. Dealers are requested to use only R12 supplied by GMSPO for warranty repairs. This high quality refrigerant will insure system performance and avoid the possibility of introducing contaminated material into the customer's A/C system. 3. Carefully test recovered R12 using the PureGuard monitor. On recovery equipment not protected by the PureGuard, always test the recovery cylinder prior to recharging a vehicle A/C system. 4. Discuss the R12 to R134a retrofit option with owners of GM vehicles listed in Retrofit Corporate Bulletin # 43-12-07D. Provide owner with a copy of the pamphlet "Converting Your Auto Air Conditioning System to Use the New Refrigerant". 5. Become familiar with retrofit procedures and exercise care in the handling of dissimilar refrigerants to prevent contamination. R134A Service Recommendations When servicing a previously retrofitted vehicle, there is concern that if all of the R12 is not completely removed prior to the retrofit procedure, it could contaminate your R134a equipment and recovery tank when a subsequent A/C repair is performed. Although the number of retrofits being performed today is minimal, the volume will increase as R12 prices rise. GM Service Technology Group is in the process of field testing a new R134a refrigerant purity tester similar to the PureGuard R12 refrigerant tester you now use. This new tool will mount to your ACR4 R134a Recovery Recycle and Recharge cart and sample all R134a refrigerant prior to recovery. It is expected that testing of this tool will be completed this year. This new tool, the Pureguard 2, will also test vehicles and your recycle tank for air contamination, which is threatening A/C system performance. High levels of air have been found in the recovery tanks on a number of R12 and R134a recovery carts. Air contamination is caused by improper recovery Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 631209 > May > 96 > A/C - R12 or R134a Service Recommendations > Page 883 procedures and short-cutting refrigerant recycling times. Use the following procedure for testing and correcting air contamination in your A/C service equipment. 1. Make certain that the ACR4 equipment has not been used for at least 12 hours. It is recommended that the equipment be left in an area where the temperature will remain constant overnight to allow the temperature of the refrigerant in the tank to stabilize. 2. Record the surrounding air temperature next to the ACR4 refrigerant tank. Important: A major assumption is that the ambient air temperature next to the tank represents the refrigerant temperature in the tank. Failure to take care in measuring the temperature could result in unnecessary work. 3. Close both liquid (blue) and vapor (red) valves on the ACR4 tank. 4. Disconnect low side (blue) service hose from the back of the ACR4. 5. Slowly disconnect the tank vapor hose (red) from the back of the ACR4 and connect it to the low side service port. 6. Open the vapor (red) valve on the tank and record the tank pressure on the low side gage. 7. Restore hoses to the original position. 8. Referring to the Table, find the ambient temperature measured in Step 2. Compare the pressure reading from Step 6 to the "maximum allowable pressure". If the pressure reading from Step 6 is less than the "maximum allowable pressure", no further action is necessary. Important: The closer the tank pressure is to the desired tank pressure, the better the A/C system will perform. 9. If the pressure reading from Step 6 exceeds the maximum allowable pressure from the Table, open both tank valves and operate the ACR4 through 4 or 5 evacuation cycles. This will activate the automatic air purge to lower the tank pressure. Important: Station should not be connected to vehicle. 10. Repeat the tank pressure checking procedure the next day to determine if the pressure has been reduced to acceptable levels. If the tank pressure has been reduced but is not acceptable, cycle with ACR4 through more evacuation cycles and recheck the next day. Continue process until acceptable pressure is obtained. If the tank pressure is not reduced through the evacuation cycling, then Kent-Moore should be contacted at 1-800-345-2233. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 531205 > May > 95 > Contaminated R12 Refrigerant - Testing & Handling Refrigerant: Technical Service Bulletins Contaminated R12 Refrigerant - Testing & Handling FILE IN SECTION: 1 - HVAC BULLETIN NO.: 53-12-05 DATE: May, 1995 SUBJECT: Contaminated R12 Refrigerant Testing and Handling MODELS: 1994 and Prior Passenger Cars and Trucks with R12 A/C Systems The J 39851 "PureGuard" R12 refrigerant monitor was recently shipped to all GM dealers as an essential tool to test R12 refrigerant. Dealers are strongly urged to install this protective device on their ACR3 or other R12 recovery equipment immediately. The PureGuard is easily installed on any recovery cart (20 minutes), requires no recovery cart modifications, is fully automatic (no training required) and does not increase the time required to perform normal A/C service procedures. Proper use of this tool can: ^ Prevent damage to your R12 recovery/recycling equipment. ^ Prevent contamination of previously recovered R12 in the recovery tank. ^ Prevent loss of your recovered R12 as contaminated refrigerant will activate automatic air purge system. ^ Prevent the spread of contaminated R12 to other vehicles you service. If your dealership has multiple R12 recovery stations which are not protected, use the PureGuard to check the refrigerant in these recovery tanks for contamination at least once each week. Simply connect the PureGuard blue service hose (that would normally be connected to the vehicle low side service port) to the red or vapor side of any recovery cart tank and run the test. It is also important to check a tank containing recovered/recycled material for purity before installation on your charging equipment. Even new R12 refrigerant purchased from sources other than GM should be tested for contamination prior to use. Sources of Contaminated R12 Refrigerant Since refrigerant testing has not been a standard practice in the mobile A/C repair industry, the amount of R12 refrigerant contamination is unknown. As R12 prices rise and supplies are depleted, it is anticipated that contaminated R12 refrigerant may become more prevalent from the following as well as other sources: ^ The use of R12 refrigerant substitutes without installation of unique service fittings and proper identification labeling. ^ Improper use of R12 substitutes, such as topping off R12 systems with R134a or other refrigerants available to "do-it-yourselfers". ^ Poor quality or contaminated new or reprocessed R12 refrigerant. R12 can and should continue to be used to service vehicles built with R12 as long as it is available. Combining any refrigerant with R12 results in a refrigerant mixture which cannot be used in an A/C system. R134a is the only substitute refrigerant approved by GM and should only be used when the appropriate retrofit service bulletin procedures are explicitly followed. Use of any other substitute refrigerant requires the purchase of additional dedicated recovery, recycling (if applicable) and charging equipment to service each substitute refrigerant used. However, you should know that the Environmental Protection Agency (EPA) has listed several products as acceptable replacements for R12 mobile A/C systems under the Significant New Alternatives Policy (SNAP). Some of these products are: R134a, R401c (a DuPont refrigerant blend) and FRIGC (another refrigerant blend). It is important to understand that the SNAP program only considers the health, safety and environmental characteristics of a chemical. It does not test for A/C system cooling performance or durability. That judgment is deferred to the vehicle manufacturer. Use of any R12 refrigerant substitute without dedicated service equipment, unique fittings, labels and refrigerant testing prior to recovery, could result in contamination of the R12 supply and the loss of the R12 recycling program. What To Do When Contamination is Detected Repeat the test to verify contaminated refrigerant is present. Clear the PureGuard following the instructions listed on the face panel, then perform a second test to verify that the vehicle A/C system contains contaminated or mixed refrigerant. Contact the vehicle owner to advise that previous A/C system repairs were apparently performed with an R12 refrigerant substitute. Suggest the owner Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 531205 > May > 95 > Contaminated R12 Refrigerant - Testing & Handling > Page 888 contact or return to the previous repair facility. Explain that environmental regulations prohibit repair facilities from discharging ozone depleting A/C refrigerants into the atmosphere. Explain that recovery of this unknown refrigerant could damage your service equipment. If the customer wishes to pursue repairs through your facility, it is recommended that the proper A/C service equipment be purchased. General Motors recommends the Kent-Moore J 41428 "Scavenger", an air operated refrigerant recovery station, be used to remove unknown refrigerants. The air operated feature reduces the hazard of recovering potentially flammable refrigerants. Dealers should evaluate the need to purchase the equipment based on the number of contaminated vehicles they encounter. As an alternative to the initial purchase of a recovery only station, dealers should check locally for A/C specialty shops which may have the equipment to service substitute or contaminated refrigerants. They may be able to provide contaminated refrigerant recovery service to the dealer. The GM Service Technology Group has tested a recovery procedure where a 15 or 30 pound DOT approved refillable tank is fully evacuated then connected to a vehicle A/C system to recover the charge. Testing has shown that even when the recovery tank is cooled down in dry ice, the procedure does not guarantee the entire charge will be recovered. Since EPA regulations require full recovery of ozone depleting substances, GM does not recommend this procedure. Contaminated Refrigerant Disposal Although A/C refrigerant testing and disposal have not been a service practice in the mobile A/C industry, It has been common in the stationary A/C service industry for many years. Listed at the end of this bulletin are companies that provide refrigerant disposal service for the stationary A/C industry. Please be advised that GM has not independently evaluated these companies and is not in any way endorsing or promoting the use of these companies. Each of these companies has expressed an interest in providing refrigerant disposal service to GM dealers. In working with the stationary A/C industry, these companies typically receive large volumes of different refrigerants that have been mixed together. Unfortunately, because the volume of material returned by the mobile A/C industry will be in much smaller quantities, the cost of handling will be greater. To arrange for return of the refrigerant, simply call the company nearest you using the phone number listed below. The company will advise you on billing and shipping procedures. Disposal cost will vary between $3.00 and $5.00 per pound plus freight and handling. Shipping charges will vary by distance and location. In general, a 7 to 10 day turn-around time on the tank can be expected. The tank can be shipped via common carrier. Documents that your refrigerant has been properly disposed of will be sent to you with the return of your tank. As an alternative, many dealerships already have contracts in place with a disposal company who manages their hazardous wastes. In these cases, the disposal service may agree to handle containers of mixed refrigerants. Initially, the local disposal companies may be surprised by this inquiry. They may want to evaluate how much material will be collected before deciding whether to provide this service. As we move forward with the practice of testing R12 refrigerant, it will take time for all the questions to be answered. STG will provide additional information as soon as it is available. Understanding The PureGuard The PureGuard is a highly sensitive instrument capable of detecting R12 with 3% or less cross-contamination with other refrigerants. Any refrigerant mixture in excess of this amount poses a threat to both your refrigerant supply and recovery equipment. The PureGuard uses a pass/fail approach when monitoring the refrigerant and is precisely calibrated to cut power to the recovery machine if it encounters R12 mixed with any substitute refrigerants. The PureGuard ignores the presence of the air, dyes or oils in the refrigerant sampled. At least 20 psi must be present in the vehicle's A/C system for the PureGuard to function. Otherwise, refrigerant cannot be introduced to the PureGuard's test chamber. If a vehicle's A/C system contains less than 20 psi, it is an indication that the vehicle's system is nearly depleted of refrigerant. Occasionally, erratic PureGuard operation or service code 002 display will be encountered when A/C system pressure is exactly 20 psi. If this occurs, simply cycle the on/off switch to reset the PureGuard. After the 30 second PureGuard warm-up cycle, proceed immediately with vehicle recovery operation. Feedback from the field has indicated PureGuard service code 002 will also be displayed if the oil drain port is not sealed. Make sure the "0" ring seal in the cap is in place and that the cap is tight. If the PureGuard fails to clear or if you experience any other problems operating the PureGuard, contact Kent-Moore Technical Service at 1-800-345-2233. The unit should not be returned without first contacting Kent-Moore to obtain return authorization. Refrigerant Disposal Locations: United States Refrigerant Reclamation Inc. 12420 North Green River Rd. Evansville, IN 47711 800-207-5931, FAX - 812-867-1463 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 531205 > May > 95 > Contaminated R12 Refrigerant - Testing & Handling > Page 889 Omega Refrigerant Reclamation 5263 North Fourth St. Irwindale, CA 91706 310-698-0991, FAX 310-696-1908 Refrigerant Management Svcs of Georgia 216 F. Atlanta Hwy. Cumming, GA 30130 Ph/FAX 800-347-5872 Refrigerant Reclaim Inc. 122 Old Stage Coach Rd. Dumfries, VA 22026 800-238-5902, FAX 703-441-0393 Gartech Refrigerant Reclamation Ctr. 2002 Platinum Garland, TX 75042 214-272-4070, FAX 214-272-8548 National Refrigerants, Inc. 11401 Roosevelt Blvd. Philadelphia, PA 19154 215-698-6620, FAX 215-602-8205 CFC Reclamation 1321 Swift North Kansas City, MO 64116 816-471-2511 Full Cycle-Global 550 James Street Lakewood, NJ 08701 908-370-3400, FAX - 908-370-3088 Refrigerant Reclaim Svcs, Inc. dba Full Cycle-Global 121 S. Norwood Drive Ft. Worth, TX 76053-7807 817-282-0022, FAX - 800-831-6182 Full Cycle-Global 2055 Silber, Ste. 109 Houston, TX 77055 713-681-7370, FAX - 713-681-9947 Full Cycle-Global 343 South Airline Hwy. Gonzales, LA 70737 504-644-5303, FAX - 504-644-1809 Full Cycle-Global 2966 Wireton Blue Island, IL 60406 708-388-8551, FAX - 708-388-8550 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431223 > Sep > 94 > A/C Refrigerant - Contamination Refrigerant: Technical Service Bulletins A/C Refrigerant - Contamination File In Section: 1 - HVAC Bulletin No.: 43-12-23 Date: September, 1994 Subject: Contaminated A/C Refrigerant Models: 1994 and Prior Passenger Cars and Trucks with R12 Air Conditioning Systems Government regulations limit the production of R12 refrigerant, commonly referred to as Freon, during 1994/1995 and restrict manufacture of new R12 material effective January 1, 1996. As R12 prices rise and supplies are depleted, it is anticipated non-approved substitute refrigerants and/or poor quality R12 material sold as new or reprocessed may become more prevalent. The Mobile Air Conditioning Society (MACS) recently expressed concern over reports of the sale of R12 refrigerant containing as high as 15% contamination by R22, a refrigerant commonly used in stationary home systems but unsuitable for use in mobile units. GM dealers should be careful to protect against contaminating their existing supplies of R12 or the A/C systems in customers' vehicles they service by dealing with reputable suppliers. All R12 refrigerant purchased for warranty repairs should be purchased through GM SPO to ensure GM quality standards are met. The use of non-approved R12 refrigerant substitutes, some of which contain flammable materials, has also been reported by MACS. These products are available to "do-it-yourselfers" who, in many cases, believe they are harmless replacements for the small cans of R12 used so commonly in the past. Once added to the A/C system, the vehicle can no longer be serviced using R12 recovery/recycling equipment without: - Risking permanent damage to recovery/recycling equipment - Contaminating the previously recovered R12 material in the recovery tank - Spreading the contamination when the recovered material is used to charge other vehicles or - Possible loss of the recovered material if the contaminated level is high enough to activate the air purge system Contaminated refrigerant also impacts customer satisfaction through poor vehicle A/C performance and loss of A/C system compressor/component durability. System or component failure resulting from the use of refrigerant which does not meet GM specification is not covered by the "New Vehicle Warranty". Unfortunately, there is no simple method to identify if a "do-it-yourselfer" or repair shop has added to or recharged a system with a non-approved refrigerant. The inability to protect against the spread of contaminated refrigerant threatens the recycling program and the industry's desire to maximize use of the remaining R12 supply. Beginning in 1993, General Motors STG, Harrison Division, Research Labs and Kent-Moore worked in conjunction with suppliers of various technologies to develop a tester to identify contaminated refrigerant in vehicle A/C systems before recovery. During development of the technology, several dealer service manager focus group studies were conducted to identify design features to best suit dealership needs. The discussions and surveys clearly indicated the desire for a dedicated instrument, permanently mounted to the refrigerant recovery cart to ensure ALL vehicles are automatically tested prior to recovering refrigerant. Testing ALL refrigerant for contamination prior to recovery is the ONLY means to ensure customer satisfaction, protect recovery equipment and avoid unintentional venting of refrigerant by your dealership. General Motors has evaluated all available technology for this project and only the J 39851 R12 "Pureguard" meets General Motors' specifications. The J 39851 R12 Pureguard Refrigerant Monitor has been classified as an essential tool and will be shipped by Kent-Moore to your dealership beginning in September of 1994. The essential price of the R12 "Pureguard" is $561 (for Canadian dealers the price is $800 Canadian). If your dealership has multiple R12 recovery equipment, additional units may be ordered from Kent-Moore for $561 at 1-800-345-2233. Features of the R12 "Pureguard" include: - Universally mounts to R12 Recovery Equipment - Automatically interrupts power to the Recovery Equipment when contaminated refrigerant is identified - Fully automatic design does not require technician action, training or interpretation - LCD displays Pureguard functions Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431223 > Sep > 94 > A/C Refrigerant - Contamination > Page 894 - Meets GM contamination sensitivity requirements - Self calibrating - Micro-processor controlled - Audio alarm alerts technician Other Refrigerant Identifiers are being advertised which may be available this A/C season. However, ONLY the Kent-Moore J 39851 R12 "Pureguard" meets General Motors' current specifications which ensure recovered refrigerant is compatible with General Motors vehicles and General Motors approved recovery systems. An R134a Pureguard Refrigerant Identifier is currently under development and is anticipated to be available in early 1995. The contamination of R134a refrigerant is not expected to be a concern until the program to retrofit R12 vehicles to R134a becomes more widely used. Future bulletins will be issued to address the recovery and disposal of contaminated refrigerant. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 331226 > Jan > 94 > A/C - Retrofitting R-12 Vehicles to R-134A Refrigerant: Technical Service Bulletins A/C - Retrofitting R-12 Vehicles to R-134A Group Ref.: HVAC Bulletin No.: 331226 Date: January, 1994 INFORMATION SUBJECT: RETROFITTING R-12 VEHICLES TO R-134a MODELS: 1994 AND PRIOR YEARS, PASSENGER CARS AND TRUCKS WITH R-12 A/C SYSTEMS There has been a great deal of information presented by the media regarding the need to retrofit vehicles produced with R-12, to a substitute refrigerant. This bulletin will outline GM's position and future plans on this subject. Most important, there is currently NO requirement to retrofit any R-12 vehicle. Vehicles built with R-12 can be serviced with R-12, as long as the refrigerant is available. At some point in time, R-12 may become either too scarce or too expensive to economically justify service on some vehicles with R-12. By that time, GM will provide you with instructions on retrofitting those vehicles from R-12 to R-134a. GM vehicle divisions, platforms, and component suppliers have been actively working on the details of retrofitting R-12 vehicles. An enormous amount of work is required to determine how hundreds of vehicle models can be satisfactorily retrofitted. Additional information will be provided as it becomes available. The following items contain important technical information that should answer many of the questions, and correct some misconceptions reported in the media. SUBSTITUTE REFRIGERANTS R-134a is the only approved substitute refrigerant that GM recommends and it should only be used if a complete retrofit procedure has been performed. None of the other refrigerants currently being marketed as replacement or drop-in substitutes for R-12 are approved for use in GM vehicles. R-12 and R-134a are not interchangeable. R-134a cannot be added to fill a low R-12 system. The combination of the two materials can cause high system pressures, which could cause damage to the system. Retrofitting an R-12 vehicle to R-134a requires careful preparation to insure that neither the vehicle nor the A/C service equipment has become contaminated. RESIDUAL MINERAL OIL The concern that mineral oil is chemically incompatible with R-134a and/or PAG lubricant has been proven to be untrue. A normal charge of mineral oil left in the A/C system after a retrofit to R-134a will not damage the system. Mineral oil, however, does not mix well with R-134a, and will not provide adequate lubrication. Tests on both the orifice tube and TXV systems show that the mineral oil parks in places such as the accumulator, and does not appreciably affect performance or damage the system. The retrofit service bulletin will specify the correct oil to be used. It is important that this oil recommendation be followed carefully. RESIDUAL R-12 Residual R-12 left in a system, due to improper retrofit service procedures, may result in system damage unless the residual R-12 is kept below the 2 percent limit specified by the Society of Automotive Engineers' Specification J-1661. New service methods are being developed to minimize the level of R-12 remaining in the A/C system after the retrofit procedure is completed. Following these new procedures will be critical to insure that the above limits are met. SYSTEM FLUSHING R-11, a material commonly used as an A/C system flushing solvent, has been found to be chemically incompatible with PAG lubricant. Technicians should be aware that residual R-11 remaining in an R-12 system will be very damaging if the vehicle is retrofitted to R-134a later in its life. For many years GM has recommended the use of in-line filters as an alternative to system flushing. SYSTEM FLUSHING, USING EITHER R-11 OR ANY OTHER FLUSHING MATERIAL, IS NOT APPROVED BY GM FOR ANY A/C SYSTEM. DESICCANT PROTECTION Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 331226 > Jan > 94 > A/C - Retrofitting R-12 Vehicles to R-134A > Page 899 It has been reported that the desiccant (moisture absorption material) used in 1992 and older R-12 A/C systems is incompatible with R-134a and PAG oil. The older desiccant was designed specifically for R-12 systems, but testing has shown that it is NOT necessary to replace the older desiccant just because the vehicle is being retrofitted to R-134a. 1993 and newer GM vehicles use desiccant designed to be compatible with both R-12 and R-134a systems. The amount of desiccant used in most GM vehicles is designed to last for at least seven years. To help maintain adequate protection for vehicles that must be retrofitted, it is recommended that the accumulator/dryer, which contains the desiccant, be replaced if the vehicle is more than five years old. "O" RINGS While continuing to service with R-12, be sure to use "O" rings and seal materials which are compatible with R-134a and PAG oil. This practice will eliminate concern in case the vehicle requires retrofitting later in its life. All "O" rings and seal materials available from GMSPO are compatible with R-134a systems. RETROFITTED SYSTEM PERFORMANCE Currently, it appears that for most GM vehicles, the retrofit procedure will require minimal changes to the existing system. Some vehicles may need additional parts and/or procedures to provide acceptable performance and/or durability. Our testing has shown that vehicles that have undergone recommended retrofit procedures will, in most climatic conditions, be minimally affected in terms of A/C performance. SERVICE POLICY Basic service policy is as follows: During Warranty - If an R-12 produced vehicle A/C system must be repaired or recharged under warranty, repairs will be completed using R-12. If R-12 is unavailable or unaffordable, GM will notify the dealer body and will pay for the warranty repair and the retrofit to R-134a. NOTE: It a customer requests that an in-warranty vehicle be converted to R-134a, and the R-12 system is functioning properly, the customer will be expected to pay for the retrofit. Out of Warranty - The cost of the conversion will be the responsibility of the customer. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 922501A > Aug > 92 > A/C - Use of Alternate Refrigerants In CFC 12 Refrigerant: Technical Service Bulletins A/C - Use of Alternate Refrigerants In CFC 12 Number: 92-250-1A Section: 0A Date: AUGUST 1992 Corporate Bulletin No.: 231205 ASE No.: A7 Subject: USE OF ALTERNATE REFRIGERANTS IN CFC 12 REFRIGERANT MOBILE AIR CONDITIONERS Model and Year: GALL MODEL YEARS - ALL PASSENGER CARS AND TRUCKS INCLUDING GEO A number of inquiries have been received concerning the use of "alternate refrigerants" as a replacement for R-12 refrigerant in General Motors air conditioning systems. Regardless of any advertised claims, there are currently no substitutes for refrigerant R-12 approved by General Motors. At the present time, only new or recycled R-12 is approved for use in General Motors R-12 air conditioning systems. Based on studies performed to date, the use of "alternate refrigerants" in General Motors R-12 air conditioning systems may result in higher system pressures, higher leak rates or incompatibility with drying and sealing materials. System performance and reliability may also be affected. Service equipment manufacturers have indicated that cross-contaminating R-12 recovery/recycling equipment with "alternate refrigerants" may damage the equipment. General Motors supports the Society of Automotive Engineers recommended service procedures for recovery and recycling of R-12. The use of known "alternate refrigerants" without proper service practices for identifying vehicle systems containing these "alternate refrigerants" and dedicated recovery equipment to service those vehicles will contaminate the recycled supply of R-12 refrigerant. Contamination of the recycled R-12 refrigerant makes the refrigerant unusable for recharging air conditioning systems and could jeopardize the recycling program. At the present time, General Motors has not approved any "alternate refrigerant" for R-12 in R-12 air conditioning systems. Therefore, R-12 systems should continue to be serviced with new or recycled R-12 only. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 904 Refrigerant: Technical Service Bulletins A/C Refrigerant - Contamination File In Section: 1 - HVAC Bulletin No.: 43-12-23 Date: September, 1994 Subject: Contaminated A/C Refrigerant Models: 1994 and Prior Passenger Cars and Trucks with R12 Air Conditioning Systems Government regulations limit the production of R12 refrigerant, commonly referred to as Freon, during 1994/1995 and restrict manufacture of new R12 material effective January 1, 1996. As R12 prices rise and supplies are depleted, it is anticipated non-approved substitute refrigerants and/or poor quality R12 material sold as new or reprocessed may become more prevalent. The Mobile Air Conditioning Society (MACS) recently expressed concern over reports of the sale of R12 refrigerant containing as high as 15% contamination by R22, a refrigerant commonly used in stationary home systems but unsuitable for use in mobile units. GM dealers should be careful to protect against contaminating their existing supplies of R12 or the A/C systems in customers' vehicles they service by dealing with reputable suppliers. All R12 refrigerant purchased for warranty repairs should be purchased through GM SPO to ensure GM quality standards are met. The use of non-approved R12 refrigerant substitutes, some of which contain flammable materials, has also been reported by MACS. These products are available to "do-it-yourselfers" who, in many cases, believe they are harmless replacements for the small cans of R12 used so commonly in the past. Once added to the A/C system, the vehicle can no longer be serviced using R12 recovery/recycling equipment without: - Risking permanent damage to recovery/recycling equipment - Contaminating the previously recovered R12 material in the recovery tank - Spreading the contamination when the recovered material is used to charge other vehicles or - Possible loss of the recovered material if the contaminated level is high enough to activate the air purge system Contaminated refrigerant also impacts customer satisfaction through poor vehicle A/C performance and loss of A/C system compressor/component durability. System or component failure resulting from the use of refrigerant which does not meet GM specification is not covered by the "New Vehicle Warranty". Unfortunately, there is no simple method to identify if a "do-it-yourselfer" or repair shop has added to or recharged a system with a non-approved refrigerant. The inability to protect against the spread of contaminated refrigerant threatens the recycling program and the industry's desire to maximize use of the remaining R12 supply. Beginning in 1993, General Motors STG, Harrison Division, Research Labs and Kent-Moore worked in conjunction with suppliers of various technologies to develop a tester to identify contaminated refrigerant in vehicle A/C systems before recovery. During development of the technology, several dealer service manager focus group studies were conducted to identify design features to best suit dealership needs. The discussions and surveys clearly indicated the desire for a dedicated instrument, permanently mounted to the refrigerant recovery cart to ensure ALL vehicles are automatically tested prior to recovering refrigerant. Testing ALL refrigerant for contamination prior to recovery is the ONLY means to ensure customer satisfaction, protect recovery equipment and avoid unintentional venting of refrigerant by your dealership. General Motors has evaluated all available technology for this project and only the J 39851 R12 "Pureguard" meets General Motors' specifications. The J 39851 R12 Pureguard Refrigerant Monitor has been classified as an essential tool and will be shipped by Kent-Moore to your dealership beginning in September of 1994. The essential price of the R12 "Pureguard" is $561 (for Canadian dealers the price is $800 Canadian). If your dealership has multiple R12 recovery equipment, additional units may be ordered from Kent-Moore for $561 at 1-800-345-2233. Features of the R12 "Pureguard" include: - Universally mounts to R12 Recovery Equipment - Automatically interrupts power to the Recovery Equipment when contaminated refrigerant is identified - Fully automatic design does not require technician action, training or interpretation - LCD displays Pureguard functions Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 905 - Meets GM contamination sensitivity requirements - Self calibrating - Micro-processor controlled - Audio alarm alerts technician Other Refrigerant Identifiers are being advertised which may be available this A/C season. However, ONLY the Kent-Moore J 39851 R12 "Pureguard" meets General Motors' current specifications which ensure recovered refrigerant is compatible with General Motors vehicles and General Motors approved recovery systems. An R134a Pureguard Refrigerant Identifier is currently under development and is anticipated to be available in early 1995. The contamination of R134a refrigerant is not expected to be a concern until the program to retrofit R12 vehicles to R134a becomes more widely used. Future bulletins will be issued to address the recovery and disposal of contaminated refrigerant. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 906 Technical Service Bulletin # 431207E Date: 970101 A/C - Retrofitting R-12 to R-134a File In Section: 1 - HVAC Bulletin No.: 43-12-07E Date: January, 1997 INFORMATION Subject: Guidelines for Retrofitting R-12 Vehicles to R-134a Models: 1984-94 Passenger Cars and Trucks (See List Below) This bulletin is being revised with the following changes: 1. Addition of all remaining GM vehicles, as listed. 2. Format rearranged for easier use. Please discard Corporate Bulletin Number 43-12-07D (Section 1 - HVAC). Car/Truck Platform Coverage Starts: 1984 - A, B, D, E, F, J, K, P, Y Carlines 1985 - C, M, N, R, S Carlines 1986 - H Carline 1987 - L, V (Allante) Car lines; M/L, G, R/V, S/T, P Truck lines 1988 - T (LeMans), E (Reatta), W Car lines; C/k, MED. Duty Truck lines 1989 - Tracker 1990 - U Van Vehicles Not Covered: T (Chevette and T1000), G RWD, C RWD, and X Car If a vehicle is not covered in the list above, GM's recommendation is that the vehicle continue to be serviced with R-12. This bulletin outlines the detailed retrofit procedures, as well as providing background information on many components and procedures. It is important to follow the bulletin, since each car and truck line has unique parts and procedures. However, the basic procedure is simple, and will become easier as you complete more retrofits. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 907 Retrofit Requirements The customer should be reminded that there is NO requirement in the U.S. to retrofit any vehicle produced with R-12. Vehicles built with R-12 can be serviced with R-12 as long as it is available (except in certain Canadian Provinces). GM has taken steps to extend the supply of R-12 and recommends that all R-12 vehicles continue to be serviced with R-12 as long as it is available. Training Video Before doing a retrofit the first time, it is recommended that you view the Certified Plus Training Video, Program number 51010.15, "R-134a Retrofit for GM Cars and Trucks". Table of Contents A. Retrofit Procedure 1. Inspect Condition of Vehicle 2. Recover the R-12 (new method) 3. Install the service port conversion fittings 4. Install any additional parts needed 5. Evacuate and recharge with new PAG or V5 retrofit oil and R-134a 6. Install the retrofit label Platform Details Compressor Replacement Chart B. General Information 1. Performance 2. Leakage 3. Desiccant 4. Improved Cooling Performance 5. PAG or V5 Oil Compatibility 6. Refrigerant Oil Level Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 908 C. Parts Information D. Warranty Information 1. Vehicle Still in Warranty 2. Customer Paid' Retrofitting Costs 3. Labor Time Information Notes on Retrofit Important: Before proceeding with any retrofit, make sure you have all component Parts required on hand to perform a proper and complete repair with Minimal downtime. R-12 Removal Prior to Retrofit To prepare a system for retrofitting, the R-12 must be recovered and the system must be completely evacuated. Evacuation is necessary to insure that small amounts of R-12 and air remaining in the system are removed. This will prevent cross contamination of the two refrigerants, which could lead to reduced A/C system reliability and performance. It is very important that the specified times for waiting after recovery and evacuation not be reduced. This time is required to sufficiently remove residual R-12 from the oil in the system. A considerable amount of testing has determined that the following procedure is required to achieve satisfactory results and conform to SAE J 1661: 1. Inspect Condition of Vehicle Install the gauge set on the high and low side ports. Use normal diagnostic procedures to find the cause of the vehicle's reported condition. One of three conditions will exist with the refrigerant system: a. System pressure correct, no leaks - proceed to Step 2 (Recovery). This would normally apply when: 1. The system must be recovered/recharged for a repair to a system other than the A/C system, or 2. Where the A/C system condition did not involve leaks, but requires recovery/recharge to replace a component. b. Compressor not operating, but some charge. Leak test to find the leak, complete Step 2 (Recovery), then correct the leak before proceeding with Step 3 (Conversion port installation). c. No charge in system - proceed with the Conversion port installation in Step 3. Use the ACR4 to evacuate for 5 minutes. If the leak can be heard, repair the leak. If the leak cannot be heard, charge with 1/2 pound of R-134a. Leak test with the J 39400 Leak Detector, recover the R-134a, repair any additional leaks found, and proceed with the evacuation in Step 5. 2. Recover the R-12 from the System Notice: THIS PROCEDURE IS DIFFERENT THAN THE NORMAL (NON-RETROFIT) RECOVERY PROCEDURE. R-12 will be recovered through the HIGH SIDE SERVICE PORT ONLY, WITH THE ENGINE RUNNING. Recovery through the low side will not effectively remove the R-12 from the accumulator, resulting in possible damage to the retrofitted system. Important: Vehicle must be above 50° F (10° C) to allow for complete recovery of the R-12. If it is not, either allow it to warm up in the shop overnight, or increase the evacuation time in Step 5.a to 30 minutes. a. Connect the recovery hose from the R-12 recovery cart (ACR3) to the middle port of the A/C gauge set. Open the oil drain valve on the ACR3 cart long enough to drain the oil. Failure to do so could cause excessive amounts of oil to build up in the separator, resulting in damage to the recovery cart compressor. b. Start the engine. Leave the hood up, and the windows open. On vehicles with manual A/C controls, set the A/C controls to normal A/C mode, high blower, and temperature control to full cold. On cars with automatic A/C controls, set the temperature to 75° F, "AUTO" mode, and manually select high blower. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 909 Make sure the vehicle compressor is engaged. Turn the cart on and start the recovery cycle. OPEN ONLY THE HIGH SIDE VALVE ON THE GAUGE SET. The vehicle system should eventually shut the compressor off. If the low side pressure drops below 15 psi, and the compressor does not turn off, turn it off now (go to "VENT" or "ECON" mode), but leave the engine running and the blower on "high". c. After the recovery cart shuts off the first time, wait 5 minutes. If the pressure on either the high or the low side rises above 0 psi, restart the recovery process. After the second shutoff, wait 2 minutes. If the pressure again rises above 0 psi, restart, and after shutoff, again wait 2 minutes. The process can be stopped when the pressure does not rise above 0 psi after 2 minutes. The engine can be shut off at this time. d. Remove the R-12 reclaim hose and the gauge set from the vehicle. Any repairs needed should be done at this time. If any components other than the compressor are replaced, they should be installed dry, and no extra oil should be added. 3. Install the Service Port Conversion Fittings Important: For GEO vehicles, skip to Step 4. Fitting installation is covered in that step. For vehicles that require a HPCOS, see Step 4. Some of these vehicles use a specific combination fitting to mount the HPCOS, which includes the high side service port fitting and the HPCOS port. The low side fitting is installed as detailed below. See "Platform Details" for further information. Important: A new tool kit, P/N J 39500-250, has been released. This kit contains the following items: ^ J 39500-71 Oil Injection Bottle Conversion Kit (includes 3 12 oz bottles, an extender tube, caps, and fittings) ^ J 39500-275 Tool kit, including the following: (See Figure 2) - J 34611-A Double ended valve core remover - J 25498-A High side adapter fitting - J 38702 Deep valve core adapter fitting Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 910 - J 41265 Thread cleaning wire brush - J 41266 Low side port thread restorer - J 41267 High side port thread restorer - J 39037 High side octagon socket - J 41256 Low side octagon socket New low profile, quick connect couplers, J 39500-20A (High side), and J 39500-24A (Low side), have been released as essential tools, to attach to the ACR4 (see Figure 3). These are much smaller couplers than the existing ones, and will allow attachment to the port fittings in much tighter quarters. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 911 Select and install the proper R-134a fittings (shown in Figure 4) from the chart below, based on how the ACR4 couplers will attach. Also, remember to check for proper hood clearance with the conversion fittings. Try the straight fittings first. The two-piece high side fitting is used when the existing fitting is screwed into the pipe fitting (some 1992, and nearly all 1993 models, use these fittings). Use the 90° elbow if the straight fitting does not allow the ACR4 couplers to connect. Fitting Type High Side Low Side Straight 52467941 52467943 Straight Two-piece 52467324 N/A 90° Elbow 52469054 52469055 The fittings should be installed as follows: a. Remove the caps from the R-12 fittings. Remove any dirt or grease from the port threads using the thread cleaning wire brush, J 41265. Inspect the fittings for thread damage. If any damage is found, use the port thread restorer (J 41266 low side, J 41267 high side) to repair the thread. For the two-piece fitting, remove the existing R-12 fitting and discard it. Use tool J 38704A (previously released, not part of the above kit) to remove the fitting. Make sure to hold the line securely to prevent damage when removing the existing fitting. If the fitting cannot be removed easily, use the saddle clamp valve listed below and seal the R-12 port and cap permanently. b. Install the selected fitting onto the existing R-12 fitting. Leave the valve core in the straight fittings, and remove the valve core when using the 90° fittings. If the valve cores need to be removed at a later time, they can be removed with the straight conversion fittings in place. On the low side straight fitting, use the J 34611-A tool to remove the core pin in the conversion fitting, then remove the core valve from the original R-12 fitting. Always recover the charge before valve core removal. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 912 Use the octagon sockets on the straight fittings (J 39037 high side, and J 41256 low side). Torque the new fitting until it seats. The fitting should seat fully BEFORE reaching 11 N.m (8 lb ft). If 11 N.m (8 lb ft) of torque is reached and the fitting has not seated, it is probable that the threads have been damaged. In this case, remove the fitting and use the thread restorer listed above. Reinstall the fitting, adding one drop of a thread locking compound such as Loctite(R) 242. The fittings (except the two-piece) have a thread locking compound applied to the threads. This compound will set up enough to restrict removal of the fitting in about 15 minutes. The fittings can now be used to evacuate the system (see Step 5). An additional type of conversion port fitting has been developed. This fitting is called a saddle clamp valve (see Figure 5). It can be clamped directly on a metal refrigerant line, and will be used if the existing fitting is damaged or is inaccessible. A drop of a thread locking compound, such as Loctite(R) 242, should be used on each bolt to prevent the threads from loosening. The R134a saddle clamp valve part numbers are: If an existing R-12 service port is not used, it must be rendered inoperative. Place several drops of a thread locking compound, such as Loctite(R) 243, in the valve core, and onto the cap threads. Secure the cap and let it set for 15 minutes. 4. Install Any Additional Parts Needed See "Platform Details" after Step 6. If a vehicle is listed as a "Basic Retrofit", no additional parts are required (except for compressors, see the Compressor Replacement Chart at the beginning of Platform Details). If no parts are required, PROCEED TO STEP 5. Compressors Compressors do not need to be replaced as part of a normal retrofit, unless indicated in the Compressor Replacement Chart. An R-12 compressor that is operating properly can, in most cases, be left in the vehicle when it is retrofitted to R134a. However, if a compressor failure is the reason the vehicle is in for service, and the vehicle will be retrofitted, OR if a vehicle has already been retrofitted with R-134a and the compressor fails at some time in the future, new compressors for use with R-134a are available. See the GMSPO Parts Catalog for specific part numbers. DO NOT use a replacement R-12 compressor for any vehicle retrofitted to R-134a (unless it is the new "oil-less" design). See "Compressor Availability" at the end of the Compressor Replacement Chart. Accumulator /Dryer If the vehicle is more than 5 years old, the Accumulator/Dryer (A/D) should be replaced to ensure that moisture is removed from the system. See the instructions for proper A/D identification in General Information. High Pressure Cut-Off Switch (HPCOS) Most trucks, and some 1984-93 B and D cars, require that a HPCOS be added to protect the refrigerant system during long idles at high temperature. The HPCOS kit (P/N 15981985) contains the switch, wire harness, heat sealing splice connectors, switch "0" ring, and installation instructions. A saddle clamp adapter (P/N 15985307), or a special dual fitting, is mounted to the high pressure line, and provides the port to mount the switch. A drop of a Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 913 thread locking compound, such as Loctite(R) 242, should be used on each bolt of the saddle clamp to prevent the threads from loosening. Some vehicles produced during the second half of the 1993 model year will already have a factory installed HPCOS. Check the back of the compressor for this switch. If present, the above switch will not have to be added. 5. Evacuate the System, and Recharge with PAG or V5 Retrofit Oil and R-134a Newly designed low profile quick connect couplers for the ACR4, J 39500-20A and J 39500-24A, have been released. These should be installed before proceeding with the evacuation. See Step 3, and Figure 3. a. Connect the R-134a cart (ACR4) to the system. Open the coupler valves on the hoses so that the pressures can be read on the gauges. On the cart, open the HIGH SIDE VALVE ONLY. DO NOT OPEN THE LOW SIDE VALVE! Program the cart for a 15 minute evacuation. Important: If the vehicle has been at outside temperatures of less than 50° F (10° C), or at high altitudes (above 3000 ft), use a 30 minute evacuation to insure complete removal of the R-12. If the vacuum pump will not start and a "H-P" reading is indicated on the ACR4 display, loosen the fitting at the high side line connection to the ACR4 to relieve pressure in the line. Tighten the fitting after pressure has been relieved. DO NOT USE THE RECOVERY MODE TO RELIEVE LINE PRESSURE. b. Start the evacuation. For a proper evacuation, the cart must pull down to 28-29 in. Hg. at sea level (reduce by 1 in. for each 1000 ft above sea level). Check the low side gauge for proper vacuum level, to make sure the new fittings are operating properly. While the evacuation is being done, the Retrofit label can be filled out and installed (see Step 6). Important: If the compressor was replaced at the same time as this retrofit, and the new compressor was shipped with the correct amount of PAG oil already in it, DO NOT add any additional oil to the system! Go to Step D. If an "oil-less" compressor was installed, add oil in Step C. A new retrofit oil for use with V5 compressor vehicles has been released. This oil will be used ONLY for retrofitted vehicles in which the original V5 compressor is retained. IT WILL NOT BE USED IF A COMPRESSOR IS REPLACED AT THE TIME OF THE RETROFIT. Failure to use this oil may significantly shorten the useful life of the compressor. Important: If the V5 Retrofit oil is not available from GMSPO, the compressor MUST BE REPLACED! To summarize the correct retrofit oil usage: ^ Compressor replaced during retrofit - NO OIL ADDED if new compressor shipped with oil - 8 oz. of PAG oil (9 oz of PAG oil with V5 compressor) added if compressor shipped without oil ("oil-less" design) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 914 ^ PAG oil used for future service if needed (mark PAG on box on label, Figure 6). ^ HR6 or R4 original compressor RETAINED - add 8 oz FAG oil to system ^ V5 original compressor RETAINED - add 9 oz V5 Retrofit oil to system. If V5 Retrofit oil is not available from GMSPO, REPLACE THE COMPRESSOR. c. Based on the above chart, add oil if needed. Use the new oil bottle and the extended tube kit, J 39500-71. Fill the bottle with at least 10 oz of oil. Attach the new bottle to the back of the ACR4, and open the oil fill valve. Allow the correct amount of oil to be drawn into the system. DO NOT allow the oil level to drop below the end of the pickup tube. This will prevent any air from being drawn into the system. If any oil was removed during the R-12 recovery evacuation steps, DO NOT add additional oil to replace it. d. Determine the correct amount of R-134a to use. Check the existing label of the vehicle for the R-12 charge amount. Use the formula {(R12 x .9) - .25 lb = R-134a} to determine the correct charge. This can also be stated as: Take 90% of the R12 charge, and subtract 1/4 lb. Follow the directions for the ACR4 cart to recharge the system. At the end of the process, "CPL" will be displayed. Close the high side valve. e. Start the vehicle, turn on the A/C system, and confirm that pressures are within normal operating ranges, as shown in the 1994 Service Manual. The 1994 Service Manuals can be used as a reference for diagnosis and specification of retrofitted systems. On some vehicles with automatic A/C controls or low charge diagnostics, the A/C compressor may not engage if any diagnostic codes were set during the retrofit. Check to see if any codes were set in either the HVAC or Engine Control systems. If they were, clear the codes following the directions in the Service Manual. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 915 f. TO INSURE AN ACCURATE CHARGE AMOUNT, IT IS IMPORTANT TO CLEAR THE ACR4 OF ANY REMAINING REFRIGERANT. Close the high side coupler valve and remove the high side hose from the vehicle. Then, open both the high and low side valves on the ACR4. After the pressures on both gages are at low side pressure, close the low side coupler valve. See Step G below, then remove the low side hose from the vehicle. Shut off the engine. Install the service port caps on the new fittings. These serve as a seal and can prevent system leaks. g. In the unlikely event that the low side fitting leaks when the coupler is removed, use the following procedure: 1. Immediately reinstall the coupler on the fitting. 2. Find the valve core remover J 34611-A. 3. Remove the coupler. 4. Use the double-ended valve core remover to turn the valve core pin counter-clockwise until the leak stops. 5. Install the cap. If the leak was substantial or continued for an extended period of time, it is highly recommended to evacuate and recharge the system to insure proper performance. If there is any question, the system can be rechecked by repeating Step F. h. Leak test any new port fittings, adapters, or valves that were installed, and any joints that were opened or repaired during the retrofit process, using tool J 39400. 6. Install the Retrofit Label The retrofit label (P/N 21030857, roll of 250) has been developed following SAF specifications to insure a smooth transition from R-12 to R-134a, and to insure a professional approach to the retrofit and a quality repair. Following the instructions in this bulletin will insure that the retrofit meets the SAE standards. Fill in the new label using a typewriter or a ball-point pen (see Figure 6). Select a location for the label that will be easily visible. Some suggested areas are the radiator support panel, an area near the existing R-12 charge label, or a flat surface near the high or low side service ports. The area selected should be a clean, underhood, painted sheet metal surface, and should be degreased and wiped down with a non-petroleum based cleaner. Do not install the label on a rubber surface. Apply the label, then apply the clear overlay to the label. Do not remove, cover, or render unreadable the existing R-12 charge label. DO cover the R-12 refrigerant charge amount on the existing label with an indelible, preferably black, marker. Platform Details Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 916 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 917 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 918 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 919 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 920 FOR ALL VEHICLES EXCEPT GEO, see the "Compressor Replacement Chart" at the end of this section. Compressor replacement requirements ARE NOT LISTED in the platform details (except for application details), except as noted below for Y car and P and Medium Duty truck. Compressor Replacement Chart Important: It is important to check the date code on the compressor. Any vehicle may have had a compressor replaced either during or after the warranty period. The date code will determine whether or not the compressor must be replaced. Compressor Availability A new compressor for use with R-134a systems will be shipped with the correct amount of PAG oil installed (see "IMPORTANT" below). Do not add any additional oil in Step 5 of the retrofit procedure if a compressor is to be replaced with a new R-134a compressor at the same time the initial retrofit is Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 921 being done. Important: During 1996, "oil-less" compressors began to be serviced with NO added oil. New part numbers will be issued, and both the box and the compressor will be clearly marked to indicate that no oil is present. If you receive one of these newer compressors, simply add the normal amount of oil to the system in Step 5 of the retrofit procedure (8 oz of PAG oil, or 9 oz of PAG oil with V5 compressor). These "oil-less" compressors are compatible with EITHER R12 or R-134a. Geo Models Compressors DO NOT HAVE TO BE REPLACED as part of the retrofit. New compressors are shipped with enough oil to accommodate the entire A/C system. Do not add additional PAG oil to the system it the compressor is being replaced. 1985-88 Nova, 1989-93 Prizm (S) 1. Using the Service Manual, remove the following components in the order given: a. Receiver/dryer. b. Loosen evaporator to compressor (suction) pipe (to be reinstalled) c. 1985-92 only: Loosen compressor to condenser (compressor discharge) pipe (to be reinstalled). d. 1985-88 only: Service Valve & Extension Housing on compressor (to be installed). e. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High and low side adapter fittings (see Step 3 of the retrofit procedure for detailed installation instructions). c. 1985-88 only: Service Valve & Extension Housing on compressor using new 0-rings. Six small 0-rings and one large 0-ring are required. d. Evaporator to compressor (suction) pipe 0-ring. e. 1985-92 Compressor to condenser (discharge) hose 0-ring. f. Receiver/dryer and 0-rings. R-134a amount: 85-92 - 650 grams (1.43 lb) 93 - 700 grams (1.54 lb) PAG oil amount: 100 cc (3.0 oz) Parts Required: Receiver/dryer: 85-88 - 94855761 89-93 - 94855762 Adapter Fittings: Low Side - 94855760 High Side - 94855759 0-Rings: 85-88 Compressor - Small 0-rings (6 required) - 94857336 - Large 0-ring - 94857337 85-93 Receiver/Dryer (2) - 94845949 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 922 85-93 Suction hose - 94855765 85-92 Discharge hose - 94845943 1985-88 Sprint, 1989-93 Metro (M) 1. Using the Service Manual, remove the following components in the order given: a. Receiver/dryer. b. Evaporator to compressor (suction) pipe. c. Compressor to condenser (compressor discharge) pipe. d. Joint service connector on compressor (to be reinstalled). e. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High and low side adapter fittings (see Step 3 of the retrofit procedure for detailed installation instructions). c. Joint service connector to compressor. Use new 0-rings. Six small 0-rings and one large 0-ring are required. d. Evaporator to compressor (suction) pipe, and new 0-ring. e. Compressor to condenser (discharge) hose and new 0-ring. f. Receiver/dryer and 0-ring. R-134a amount: 500 grams (1.10 lb) PAG oil amount: 100 cc (3.0 oz) Parts Required: Receiver/dryer: 85-86 - 91172081 87-88 - 91172079 89-93 - 96068480 Adapter Fittings: Low Side - 91172092 85-88 - High Side - 91172094 89-93 - High Side - 52467941 0-Rings: Compressor - Small 0-rings (6 required) - 91172095 - Large 0-ring - 96068915 Receiver/Dryer (2) - 96068488 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 923 89-93 - Suction hose - 96068490 89-93 - Discharge hose - 96068489 Suction hose: 85-86 - 91172086 85-86 Dealer installed: 91172087 87-88 - 91172088 89-93 - w/turbo - 96069121 - w/o turbo - 91172089 Discharge hose: 85-86 - 91172082 85-86 Dealer installed: 91172083 87-88 - 91172084 89-93 - 96069024 1989-93 Tracker 1. Using the Service Manual, remove the following components in the order given: a. Receiver/dryer. b. Evaporator to compressor (suction) pipe. c. Compressor to condenser (compressor discharge) pipe. d. Joint service connector on compressor (to be reinstalled). e. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High and low side adapter fittings (see Step 3 of the Retrofit procedure for detailed installation instructions). c. Joint service connector to compressor. Use new 0-rings. Six small 0-rings and one large 0-ring are required. d. Evaporator to compressor (suction) pipe, and new 0-ring. e. Compressor to condenser (discharge) hose and new 0-ring. f. Receiver/dryer and 0-ring. R-134a amount: 550 grams (1.21 lb) PAG oil amount: 100 cc (3.0 oz) Parts Required: Receiver/dryer - 91172080 Adapter, Low Side - 91172092 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 924 Adapter, High Side - 91172093 0-Rings: Compressor - Small (6) - 91172095 Large - 96068915 Receiver/dryer (2) - 96068488 Suction hose - 96068490 Discharge hose - 96068489 Suction hose - 91172091 Discharge hose - 91172085 1985-89 Spectrum and 1990-93 Storm (R) 1. Using the Service Manual, remove the following components in the order given: a. Condenser (Storm) or radiator grille (Spectrum) (to be reinstalled). b. Triple switch (Storm) or dual pressure switch (Spectrum) (to be reinstalled). c. Receiver/dryer. d. Evaporator to compressor (suction) pipe. e. Check valve from high side service valve (discard). f. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High side adapter fitting (see Step 3 of the retrofit procedure for detailed installation instructions). Low Side - Part of suction hose c. Evaporator to compressor (suction) pipe, and new 0-rings. d. Receiver/dryer and 0-rings. e. Triple switch or dual switch, and new 0-ring. f. Condenser or radiator grille. R-134a amount: 91 - 500 grams (1.10 lb) 92-93 - 600 grams (1.32 lb) PAG oil amount: 150 cc (4.50 oz) Parts Required: Receiver/dryer: 85-89 - 97104795 90-91 - 97104797 92-93 - 97104798 Adapter, High Side: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 925 85-89 - 97104794 90-93 - 97104793 Adapter, Low Side: Part of Hose Asm. 0-rings: Receiver/dryer 85-91 - 94154048 92-93 - 94461700 Switch/pipe - 94461902 Suction hose: 85-86: 1.5L - 97104799; 1.6L - 97104800 90-93: 1.6L - 97104801; 1.8L - 97104803 B. General Information Several items affecting the performance and durability of the system should be considered: 1. Performance When performed properly, the retrofit from R-12 to R-134a will have minimal effect on the system's performance in most climatic conditions found in the United States and Canada. 2. Leakage Experience has shown that most leakage in an A/C system is due to leaks at the joints, or through a small leak in a hose, usually at the coupling. The R-134a molecules are smaller than R-12, and a small leak may result in a faster loss of refrigerant with R-134a. Because of this, it is very important to leak check all vehicles using the J 39400 leak detector, BEFORE the retrofit is performed, and repair any leaks found. "0" rings and hoses used in most GM vehicles are compatible with R-134a and do not need replacement during a retrofit. "0" rings or hoses installed in previous repairs may have been of non-compatible materials if GM parts were not used and will be more likely to deteriorate and leak than the original equipment materials. All "0" rings and hoses available through GMSP0 are compatible with R-134a. Remember that the normal policy is to replace the "0" rings whenever a joint is opened for any reason. 3. Desiccant You may have heard that the currently used desiccant in the accumulator is not compatible with R-134a. Extensive testing has shown that it is, in fact, suitable for use with R-134a, once it has been in service in an R-12 system. The accumulator in these models will not have to be changed during the retrofit procedure, unless the vehicle is more than 5 years old. Vehicles more than 5 years old should have the A/D replaced to add new desiccant for proper system drying. In the event that an accumulator/dryer (A/D) needs to be replaced on a retrofitted system in the future, only A/D's with XH-7 desiccant should be used. The service parts for the 1993 vehicles contain only XH-7 desiccant. The parts for the 1992 and older vehicles may contain either XH-5 or XH-7. Parts containing XH-7 can be identified (see Figure 1) by 1) an "A" printed on the top of the A/D; or 2) if there is a label on top of the A/D, there will be a square with an "A" inside; or 3) if there is a time code and date printed on top of the A/D just under the "Harrison" logo, the A/D contains XH-7. A/D's containing XH-5 can still be used on R-12 vehicles. 4. Improved Cooling Performance There have been service bulletins issued in the past with information improving the cooling performance of existing R-12 systems. These bulletins can also be used to improve the performance of retrofitted vehicles in high ambient temperature climates. 5. PAG or V5 Oil Compatibility Contrary to information published to date outside of General Motors, mineral oil and PAG or V5 oil ARE chemically compatible. The mineral oil left in the system after reclaiming the R-12 can remain in the system with no harmful effects. However, the mineral oil will not mix with the R-134a, and so will not circulate and perform its lubricating function. Testing has shown that most of the mineral oil will eventually collect in the Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 926 accumulator. The system will operate properly as long as refrigerant charge amounts are strictly adhered to. 6. Refrigerant Charge Level The retrofit R-134a charge level is more critical than with R-12 systems. Overcharging may push the mineral oil out of the AID, and cause it to circulate as a liquid. This is more likely to result in compressor damage. Undercharging may lead to loss of performance. It is very important to clear the hoses during the charging operation, to insure that all the refrigerant is delivered to the vehicle A/C system. This is covered in Step 6D of the Retrofit Procedure. C. Parts Information Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 927 Important: All of the following parts are NOT NEEDED for a normal retrofit. Follow the bulletin procedures to determine which parts you need! Individual vehicle kits are not necessary, since most of the parts are generic and only a few parts are needed for most vehicles. GEO Parts are listed in "Platform Details." Parts are currently available from GMSPO. D. Warranty Information 1. Vehicle Still Within the Original New Vehicle Limited Warranty Period When GM models for the years listed in the bulletin require repairs to the refrigerant system and the vehicles are still covered under the New Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 928 Vehicle Limited Warranty, dealers are instructed to proceed as follows: Important: On vehicles equipped with A/C systems NOT produced by GM (i.e., rear A/C systems in van conversions), consult the manufacturer of that A/C system for retrofit guidelines. ^ Offer the customer the option of repairing and recharging the system with R12, or retrofitting after repair and recharging with R-134a at no additional charge. ^ Provide the owner with, and review the information contained in, the "Converting Your Auto Air Conditioning System to Use the New Refrigerant" brochure. (Brochure, Form GM-0011, can be ordered free of charge from GM Fulfillment HQ, Phone 1-800-269-5100). ^ Record the customer's choice on the repair order and, as with all properly completed repair orders, ask the customer to sign on the appropriate line acknowledging the repairs requested. ^ Under no circumstances should the retrofit to R-134a be performed unless the customer has had the option explained prior to repair. Once the vehicle has been retrofitted to R-134a, a significant expenditure would be incurred to go back to R-12, in the event the customer has changed his/her mind. THIS OFFER APPLIES ONLY TO VEHICLES REQUIRING A/C REFRIGERANT SYSTEM REPAIRS UNDER THE TERMS OF THE NEW VEHICLE LIMITED WARRANTY. It is not a special policy, and any existing deductibles still apply. This is simply an option being offered to the customer during the warranty period at this time. GM reserves the right to terminate this offer at any time. If the R-12 refrigerant system does not require discharging for a warranty repair, but the customer requests a retrofit to R-134a, the retrofit WOULD BE PERFORMED AT THE CUSTOMER'S EXPENSE, EVEN DURING THE WARRANTY PERIOD. 2. Customer Paid Retrofitting Costs If the customer requests a retrofit to R-134a, for a specific vehicle whose retrofit parts and procedures have been released in this bulletin, the customer would be expected to pay the costs to retrofit under the following conditions: ^ The vehicle is no longer covered by the terms of the New Vehicle Limited Warranty. ^ The vehicle is covered by warranty, but the repair covered under the warranty does not require evacuating and recharging the refrigerant system. 3. Labor Time Information For Vehicles Repaired Under Warranty: Use existing labor operations for correcting the original condition. The quantity of R-134a used should be charged to the normal labor operation (not D4500), just as if it were R-12. Use D4500, 0.3 HR., to charge for parts and labor, for all of the following items: ^ Additional time for recovery of R-12 to meet SAE standards; ^ Install high and low side service port converter fittings; ^ Add PAG or V5 retrofit oil; ^ Complete label information and install. Add 0.2 hours to D4500 for installation of the HPCOS. Use T5321, 0.3 HR., for the Pontiac Bonneville hood seal installation. ANY PARTS OR LABOR TIME OTHER THAN THOSE LISTED ABOVE SHOULD BE CHARGED TO THE REGULAR LABOR OPERATION CORRESPONDING TO THE ORIGINAL CONDITION THAT 1S BEING REPAIRED. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 929 Technical Service Bulletin # 631209 Date: 960501 A/C - R12 or R134a Service Recommendations File In Section: 1 - HVAC Bulletin No.: 63-12-09 Date: May, 1996 INFORMATION Subject: Service Issues for Vehicles with R12 or R134a Air Conditioning Systems Models: 1988-96 Passenger Cars and Trucks R12 Service Recommendations As you know, production of R12 refrigerant ceased on December 31, 1995. Although R12 will no longer be manufactured, there is a reserve supply of R12 available. This reserve, along with strict A/C repair service adherence to proper refrigerant recycling procedures, should assure continued availability to meet consumers' needs. R12 can and should continue to be used to service vehicles built with R12 A/C systems as long as it is available. If R12 is no longer available or affordable, a system retrofit utilizing R134a is recommended. R134a IS THE ONLY SUBSTITUTE REFRIGERANT RECOMMENDED BY GM FOR USE IN GM VEHICLE A/C SYSTEMS, AND THEN ONLY AFTER FOLLOWING THE PROPER RETROFIT PROCEDURES FOR THE SPECIFIC MODEL. All new vehicle manufacturers have chosen R134a for retrofit. One of the key reasons is to protect both the service industry and consumers from the high costs that would result from purchasing equipment necessary to service multiple refrigerants. This position also reduces the threat of recycled refrigerant contamination. GM currently offers a simple, low cost R12 to R134a retrofit on many of its late model, front wheel drive passenger cars. Dealers should discuss this capability with owners of these specific models, listed in Retrofit Corporate Bulletin # 43-12-07D, whenever a repair to the A/C refrigerant system is required. Early retrofit of these specific models will aid in prolonging availability of the R12 supply and provide dealer service technicians the opportunity to become more familiar with the proper procedures for performing a retrofit. Remember - R12 and R134a refrigerant are not interchangeable! They cannot be mixed together. In fact, despite the claims of some refrigerant manufacturers, no proposed R12 refrigerant substitute can be added to, mixed with or used to "top off" an R12 system. Under provisions of law covering the service of refrigerants, mixing dissimilar refrigerant products during service is prohibited. To Summarize GM R12 Service Policy 1. Service R12 vehicles with good quality new or recycled R12 as long as it is available. 2. Purchase R12 from a reliable supplier. GMSPO has a supply of high quality R12 available. Dealers are requested to use only R12 supplied by GMSPO for warranty repairs. This high quality refrigerant will insure system performance and avoid the possibility of introducing contaminated material into the customer's A/C system. 3. Carefully test recovered R12 using the PureGuard monitor. On recovery equipment not protected by the PureGuard, always test the recovery cylinder prior to recharging a vehicle A/C system. 4. Discuss the R12 to R134a retrofit option with owners of GM vehicles listed in Retrofit Corporate Bulletin # 43-12-07D. Provide owner with a copy of the pamphlet "Converting Your Auto Air Conditioning System to Use the New Refrigerant". 5. Become familiar with retrofit procedures and exercise care in the handling of dissimilar refrigerants to prevent contamination. R134A Service Recommendations When servicing a previously retrofitted vehicle, there is concern that if all of the R12 is not completely removed prior to the retrofit procedure, it could contaminate your R134a equipment and recovery tank when a subsequent A/C repair is performed. Although the number of retrofits being performed today is minimal, the volume will increase as R12 prices rise. GM Service Technology Group is in the process of field testing a new R134a refrigerant purity tester similar to the PureGuard R12 refrigerant tester you now use. This new tool will mount to your ACR4 R134a Recovery Recycle and Recharge cart and sample all R134a refrigerant prior to recovery. It is expected that testing of this tool will be completed this year. This new tool, the Pureguard 2, will also test vehicles and your recycle tank for air contamination, which is threatening A/C system performance. High levels of air have been found in the recovery tanks on a number of R12 and R134a recovery carts. Air contamination is caused by improper recovery Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 930 procedures and short-cutting refrigerant recycling times. Use the following procedure for testing and correcting air contamination in your A/C service equipment. 1. Make certain that the ACR4 equipment has not been used for at least 12 hours. It is recommended that the equipment be left in an area where the temperature will remain constant overnight to allow the temperature of the refrigerant in the tank to stabilize. 2. Record the surrounding air temperature next to the ACR4 refrigerant tank. Important: A major assumption is that the ambient air temperature next to the tank represents the refrigerant temperature in the tank. Failure to take care in measuring the temperature could result in unnecessary work. 3. Close both liquid (blue) and vapor (red) valves on the ACR4 tank. 4. Disconnect low side (blue) service hose from the back of the ACR4. 5. Slowly disconnect the tank vapor hose (red) from the back of the ACR4 and connect it to the low side service port. 6. Open the vapor (red) valve on the tank and record the tank pressure on the low side gage. 7. Restore hoses to the original position. 8. Referring to the Table, find the ambient temperature measured in Step 2. Compare the pressure reading from Step 6 to the "maximum allowable pressure". If the pressure reading from Step 6 is less than the "maximum allowable pressure", no further action is necessary. Important: The closer the tank pressure is to the desired tank pressure, the better the A/C system will perform. 9. If the pressure reading from Step 6 exceeds the maximum allowable pressure from the Table, open both tank valves and operate the ACR4 through 4 or 5 evacuation cycles. This will activate the automatic air purge to lower the tank pressure. Important: Station should not be connected to vehicle. 10. Repeat the tank pressure checking procedure the next day to determine if the pressure has been reduced to acceptable levels. If the tank pressure has been reduced but is not acceptable, cycle with ACR4 through more evacuation cycles and recheck the next day. Continue process until acceptable pressure is obtained. If the tank pressure is not reduced through the evacuation cycling, then Kent-Moore should be contacted at 1-800-345-2233. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Page 931 Refrigerant: Specifications MAKE, YEAR & MODEL Kg. Oz. CHEVROLET 1992 Beretta, Corsica 1.2 42 1992-91 Caprice 1.4 50 1992-90 Lumina 1.0 36 1992-88 Camaro, Corvette 1.0 36 1992-86 Cavalier 1.0 36 1991-89 Beretta, Corsica 1.3 44 1990-86 Celebrity 1.1 40 1990-82 Caprice 1.6 54 1989-87 Spectrum 0.8 28 1988-87 Beretta, Corsica, Corvette 1.0 36 1988-85 Sprint 0.7 24 1988-83 Monte Carlo 1.6 54 1987-83 Camaro 1.4 48 Chevette 1.0 36 1986-85 Spectrum 0.7 24 1986-83 Impala, Malibu 1.6 54 1985-83 Cavalier, Celebrity, Corvette 1.3 44 Citation 1.3 44 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Oil Charge Data Table System System ................................................................................................................................................. ............................................................................ 8 oz Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 936 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL TYPE ^ R-12 refrigerant oil, 525 viscosity (See Note). NOTE: If vehicle has been converted to R-134a use PAG (Polyalkaline Glycol) synthetic refrigerant oil (GM Part No. 12345923) or equivalent. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Hydraulic System Bleeding Brake Bleeding: Service and Repair Hydraulic System Bleeding Manual Bleeding Pressure bleeding is recommended for all non-ABS hydraulic systems. However, if a pressure bleeder is unavailable, use the following procedure. Brake fluid damages painted surfaces. Immediately clean any spilled fluid. 1. Remove vacuum reserve by pumping brakes several times with engine off. 2. Fill master cylinder reservoir with clean brake fluid. Check fluid level often during bleeding procedure; do not let reservoir fall below half full. 3. If necessary, bleed master cylinder as follows: a. Disconnect master cylinder forward brake line connection until fluid flows from reservoir. Reconnect and tighten brake line. b. Instruct an assistant to slowly depress brake pedal one time and hold. c. Crack open front brake line connection again, purging air from cylinder. d. Retighten connection and slowly release brake pedal. e. Wait 15 seconds, then repeat until all air is purged. f. Bleed the rearward (nearest the cowl) brake line connection by repeating steps a through e. 4. Loosen, then slightly retighten bleeder valves at all four wheels. Repair any broken, stripped or frozen valves at this time. 5. Proceed to appropriate wheel first and follow set sequence according to the bleeding sequence. Bleeding Sequence: RR-LF-LR-RF Fig. 20 Bleeding Brakes 6. Place transparent tube over bleeder valve, then allow tube to hang down into transparent container, Fig. 20. Ensure end of tube is submerged in clean brake fluid. 7. Instruct an assistant to slowly depress brake pedal one time and hold. 8. Crack open bleeder valve, purging air from cylinder. Retighten bleeder screw and slowly release pedal. 9. Wait 15 seconds, then repeat steps 7 and 8. Repeat these steps until all air is bled from system. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Hydraulic System Bleeding > Page 941 Fig. 21 Installing Pressure Bleeder Adapter Fig. 20 Bleeding Brakes Pressure Bleeding, Non-ABS Only 1. Loosen, then slightly retighten bleeder valves at all four wheels. Repair any broken, stripped or frozen valves at this time. 2. Using a diaphragm type pressure bleeder, install suitable bleeder adapter to master cylinder, Fig. 21. 3. Charge bleeder ball to 20-25 psi. 4. Connect pressure bleeder line to adapter. 5. Open line valve on pressure bleeder, then depress bleed-off valve on adapter until a small amount of brake fluid is released. 6. Raise and support vehicle. 7. Proceed to appropriate wheel first and follow set sequence according to Wheel Bleeding Sequence. 8. Place transparent tube over bleeder valve, then allow tube to hang down into transparent container, Fig. 20. Ensure end of tube is submerged in clean brake fluid. 9. Open bleeder valve 1/2 to 3/4 turn and allow fluid to flow into container until all air is purged from line. Wheel Bleeding Sequence Rear wheel drive models except Corvette: if manual bleeding, RR-LR-RF-LF; if pressure bleeding, bleed front brakes together and rear brakes together. Front wheel drive models except Spectrum: RR-LF-LR-RF. 1989 Corvette: RF-RR-LR-LF. Spectrum: LF-RR-RF-LR. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Hydraulic System Bleeding > Page 942 Flushing Hydraulic System If brake fluid is old, rusty or contaminated, or whenever new parts are installed in hydraulic system, the system must be flushed. Bleed brakes, allowing at least one quart of clean brake fluid to pass through system. Any rubber parts in hydraulic system which were exposed to contaminated fluid must be replaced. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Hydraulic System Bleeding > Page 943 Brake Bleeding: Service and Repair Master Cylinder Bleeding This procedure can be performed with master cylinder on or off vehicle. CAUTION: Brake fluid will damage painted surfaces. Brake fluid can also damage electrical connections. Shop cloths and clean containers should be used to prevent spillage of brake fluid. 1. Disconnect brake lines at master cylinder, if necessary. 2. Connect suitable lengths of brake lines to master cylinder and immerse other ends of lines in master cylinder reservoirs. 3. Apply master cylinder pushrod or brake pedal with full strokes until air bubbles have disappeared in reservoirs. It may require 20-30 applications to fully eliminate air bubbles. 4. Remove bleeding lines from master cylinder, then install master cylinder on vehicle, if necessary, and connect brake lines. 5. Fill the reservoir. Normal bleeding procedures should be followed after the master cylinder is installed. For additional information see Bench Bleeding. See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Fundamentals and Basics Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Page 944 Brake Bleeding: Fundamentals and Basics BENCH BLEEDING Why A master-cylinder will develop little or no pressure if air is trapped in cylinder bore. Normal brake bleeding will not remove air trapped within the master-cylinder. How Clamp the master-cylinder securely in a vice. It is usually best to clamp the side of the vice onto the flat surface that is used to secure the master-cylinder to the brake booster. There are two basic methods for bleeding master-cylinder, one utilizes stroking the master-cylinder to expel air from the cylinder bore while the other utilizes a large syringe to backflush fluid from the outlet ports to the reservoir. Stroking Fill the master-cylinder with clean brake fluid. - The brake line fittings on the master-cylinder should be capped or plugged. NOTE: Special "bench bleeding" plastic fittings are available which allow for recirculating the brake fluid back into the reservoir. - Using a dull object, slowly stroke the master-cylinder piston, air and brake fluid will be expelled from the brake line fittings. Prior to releasing the piston plug or cap the outlet ports. - Repeat this procedure 8-10 times or until no air is emitted from the outlet ports. - When finished, cap the outlet ports and install the master-cylinder. Syringe Fill the syringe (one especially designed for brake bleeding) with clean brake fluid. - Insert the end of the syringe into one of the outlet ports on the master-cylinder. - Slowly compress the syringe and back flush the brake fluid through the master-cylinder. - A combination of air and brake fluid will be emitted from the inlet port in the fluid reservoir. - Repeat this procedure until only brake fluid is emitted into the reservoir. Cap the outlet ports and install the master-cylinder. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling the SIR System Air Bag(s) Arming and Disarming: Service and Repair Disabling the SIR System The diagnostic energy reserve module (DERM) can maintain voltage to cause a system deployment for up to ten minutes after the ignition switch is turned off and the battery is disconnected. Servicing the SIR system during this period may result in accidental deployment and personal injury. 1. Ensure front wheels are pointed straight ahead. 2. Turn ignition switch to Lock position and remove SIR or AIRBAG fuse. 3. Remove lower left sound insulator. 4. Remove connector position assurance (CPA) lock and disconnect yellow two-way SIR harness connector at base of steering column. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling the SIR System > Page 949 Air Bag(s) Arming and Disarming: Service and Repair Enabling the SIR System 1. Connect yellow two-way SIR harness connector and install CPA lock. 2. Install left sound insulator. 3. Install SIR fuse. 4. Turn ignition switch to Run position and ensure ``Inflatable Restraint'' lamp flashes 7-9 times and then remains off. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 955 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 956 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 957 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 958 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 959 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 960 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 961 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 962 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 963 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 964 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 965 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 966 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 967 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 968 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 969 Circuit Breaker: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 970 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 971 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 972 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 973 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 974 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 975 Circuit Breaker: Electrical Diagrams Fuse Block Details: RDO 1 Fuse, S/LP Fuse, And PWR ACC Circuit Breaker Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 976 Fuse Block Details: WDO Circuit Breaker And HTR-A/C Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > DRL In-Line Fuse A Fuse: Locations DRL In-Line Fuse A LH Side Of Engine Compartment. LH Side Of Engine Compartment, By Strut Tower Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > DRL In-Line Fuse A > Page 983 Fuse: Locations DRL In-Line Fuse B LH Side Of Engine Compartment. LH Side Of Engine Compartment, By Strut Tower Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > DRL In-Line Fuse A > Page 984 Fuse: Locations Fuel Pump Inline Fuse LH Front Of 3. LH Front Of Dash On Relay Bracket Applicable to: 1L/V6-192 Dash. 1991 Sunbird Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 987 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 988 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 989 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 990 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 991 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 992 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 993 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 994 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 995 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 996 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 997 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 998 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 999 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1000 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1001 Fuse: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1002 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1003 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1004 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1005 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1006 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1007 Fuse: Electrical Diagrams Fuse Block Details: Wiper Fuse, Cruise Fuse And RDO 2 Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1008 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/U Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1009 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/u Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1010 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/U Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1011 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/u Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1012 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/U Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1013 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/u Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1014 Fuse Block Details: WDO Circuit Breaker And HTR-A/C Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1015 Fuse Block Details: RDO 1 Fuse, S/LP Fuse, And PWR ACC Circuit Breaker Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1016 Fuse Block Details: Wiper Fuse, Cruise Fuse And RDO 2 Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1017 Fuse Block Details: RDO 1 Fuse, S/LP Fuse, And PWR ACC Circuit Breaker Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1018 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/U Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1019 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/u Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1020 Fuse Block Details: Wiper Fuse, Cruise Fuse And RDO 2 Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations Fuse Block: Locations Convenience Center Location. Behind I/P, Near Top Of LH Shroud Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fusible Link A Fusible Link: Locations Fusible Link A LH Front Of 2. Engine Harness, At Starter Solenoid Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fusible Link A > Page 1028 Fusible Link: Locations Fusible Link B LH Front Of 2.2L At Starter Solenoid Applicable to: 2L/4-134 Engine. 1992 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fusible Link A > Page 1029 Fusible Link: Locations Fusible Link C LH Front Of 2.2L At Starter Solenoid Applicable to: 2L/4-134 Engine. 1992 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fusible Link A > Page 1030 Fusible Link: Locations Fusible Link E LH Front Of 2. At Starter Solenoid Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fusible Link A > Page 1031 Fusible Link: Locations Fusible Link A LH Front Of 2. Engine Harness, At Starter Solenoid Applicable to: 2L/4-134 Engine. 1991 Cavalier Fusible Link B LH Front Of 2.2L At Starter Solenoid Applicable to: 2L/4-134 Engine. 1992 Cavalier Fusible Link C Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fusible Link A > Page 1032 LH Front Of 2.2L At Starter Solenoid Applicable to: 2L/4-134 Engine. 1992 Cavalier Fusible Link E LH Front Of 2. At Starter Solenoid Applicable to: 2L/4-134 Engine. 1991 Cavalier Fusible Link G LH Front Of 2. At Starter Solenoid Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fusible Link A > Page 1033 Applicable to: 2L/4-134 Engine. 1991 Cavalier Fusible Link L LH Front Of Dash, At Battery Junction Block Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation Some vehicles use a buzzer or indicator lamp to indicate a low coolant level condition. The buzzer or lamp is activated by a sensor, located in the radiator, when the coolant level becomes one quart or more low. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Coolant Level Indicator Lamp > Component Information > Description and Operation > Page 1038 Coolant Level Indicator Lamp: Service and Repair This lamp will be illuminated when engine coolant level in the radiator drops below a pre-determined level. To turn lamp "OFF," check cooling system, then add coolant to bring system to proper level. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Service and Repair Malfunction Indicator Lamp: Service and Repair The check engine lamp will be illuminated when the ignition switch is placed in the On position. When the engine is started, the lamp should go off. If the lamp remains On for 10 seconds or constantly after the engine is started, the self diagnosis system has detected a problem and has stored a code in the system Electronic Control Module (ECM). After diagnosis and repair, the ECM memory can be cleared of codes as follows: On models except Cadillac with DEFI and 1986-88 Buick Reatta/Riviera and Oldsmobile Toronado/Trofeo, remove the ECM fuse or disconnect the battery ground cable for approximately 30 seconds, with ignition switch in the Off position. It should be noted, if battery ground cable is disconnected to clear codes, components such as clocks, electronically tuned radios etc., will have to be reset. On vehicle that are equipped as such, the ECM power feed is connected by a pigtail, inline fuse holder, at the positive battery terminal. To clear codes within the ECM system and protect the components that need resetting, disconnect the inline fuse. On 1980-85 Cadillac models with DEFI engines, depress Electronic Climate Control Off and Hi buttons to clear codes. On 1986-92 Cadillac DeVille and Fleetwood models, depress Off and Lo button on the Electronic Climate Control to clear stored BCM codes. Depress Off and Hi to clear stored ECM codes. On Cadillac Eldorado and Seville and 1986-88 Buick Reatta/Riviera and Oldsmobile Toronado/Trofeo models, the stored codes are cleared during the self-diagnostic procedure. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 931693E > Apr > 93 > Tires - Slipping on Rim Tires: Customer Interest Tires - Slipping on Rim Number: 93-169-3E Section: 3E Date: APRIL 1993 Corporate Bulletin No.: 393501 ASE No.: A4 Subject: TIRES SLIPPING ON WHEELS (USE PROPER TIRE MOUNTING PROCEDURE) Model and Year: 1988-93 ALL PASSENGER CARS AND LIGHT DUTY TRUCKS Some incidents of tires slipping (rotating) on wheels have been reported on 1988-93 passenger cars and light duty trucks. Most incidents have occurred when driven aggressively immediately after tire mounting. Hard acceleration and/or braking is usually required. This condition will affect wheel balance, which could result in a vibration. To reduce the chance of tires rotating on their wheels, any excess lube should be wiped from the tire and rim after tire mounting, but before inflating to seat the bead. (Never exceed 40 psi to seat the bead.) Also, the vehicle should not be driven aggressively for at least four hours after tire mounting to allow the lube to dry. GM Goodwrench Rubber Lubricant, p/n 12345884, is the recommended lube for tire mounting. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Diagnostic Procedures Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 1055 Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 1056 condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 1057 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 1058 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 1059 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 1060 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures Tires: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures > Page 1066 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures > Page 1067 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures > Page 1068 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures > Page 1069 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures > Page 1070 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05-03-10-020C > Apr > 10 > Wheels/Tires - Use of Nitrogen Gas in Tires Tires: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05-03-10-020C > Apr > 10 > Wheels/Tires - Use of Nitrogen Gas in Tires > Page 1075 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00-00-90-002J > Jan > 09 > Tires - Correct Inflation Pressure Information Tires: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00-00-90-002J > Jan > 09 > Tires - Correct Inflation Pressure Information > Page 1080 ^ 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 433502 > Jul > 94 > Tires - Speed Rated Information Tires: All Technical Service Bulletins Tires - Speed Rated Information Group Ref.: 3 - Steering/Suspension Bulletin No.: 433502 Date: July, 1994 INFORMATION SUBJECT: SPEED RATED TIRES MODELS: 1995 AND PRIOR YEAR PASSENGER CARS AND LIGHT DUTY TRUCKS All original equipment passenger car and light duty truck tires used by General Motors have a speed rating symbol molded on their sidewall. This speed symbol, along with the tire's load index, make up the service description that follows the tire's size. The original equipment tire size, speed rating, and recommended inflation pressure are listed on the tire placard usually located on the driver's door edge. WHEN REPLACING TIRES, NEVER INSTALL A TIRE THAT IS A SMALLER SIZE OR LESSER SPEED RATING THAN THAT USED AS ORIGINAL EQUIPMENT. As in the past, it is recommended that replacement tires have a TPC (Tire Performance Criteria) number on the sidewall that is identical to that on the original tires. Common speed rating on tires used by General Motors are as follows: (see illustration) IMPORTANT: Most base all season tires and touring tires used by GM are S rated. Performance tires will usually have a higher speed rating. High performance tires are usually Z rated. Z rated tires carry the Z symbol within the tire size, rather than after the size in the service description. These speeds apply only at the tire's full pressure. An underinflated tire will not meet its speed rating capability. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 323501 > Dec > 93 > Tires - Manufacturers' Assistance Tires: All Technical Service Bulletins Tires - Manufacturers' Assistance Group Ref.: Steering/ Suspension Bulletin No.: 323501 Date: December, 1993 INFORMATION SUBJECT: TIRE MANUFACTURERS' CONTACTS FOR ASSISTANCE MODELS: 1991-94 PASSENGER CARS AND TRUCKS General Tire has established a "Tire Fix" Department to assist you with anything from a tire adjustment to the location of the nearest General Tire dealer. "Tire Fix" representatives are available Monday through Friday from 8:00 A.M. to 6:00 P.M. Eastern Time at 1-800-847-3349. A General Tire Brochure is provided for review with all appropriate dealer personnel. A single contact point at General Tire can assist you with most aspects of their product to satisfy your customers' needs. Other tire manufacturers can be contacted for assistance at the Toll Free Numbers listed in illustration: Please retain this information for future reference. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 931693E > Apr > 93 > Tires - Slipping on Rim Tires: All Technical Service Bulletins Tires - Slipping on Rim Number: 93-169-3E Section: 3E Date: APRIL 1993 Corporate Bulletin No.: 393501 ASE No.: A4 Subject: TIRES SLIPPING ON WHEELS (USE PROPER TIRE MOUNTING PROCEDURE) Model and Year: 1988-93 ALL PASSENGER CARS AND LIGHT DUTY TRUCKS Some incidents of tires slipping (rotating) on wheels have been reported on 1988-93 passenger cars and light duty trucks. Most incidents have occurred when driven aggressively immediately after tire mounting. Hard acceleration and/or braking is usually required. This condition will affect wheel balance, which could result in a vibration. To reduce the chance of tires rotating on their wheels, any excess lube should be wiped from the tire and rim after tire mounting, but before inflating to seat the bead. (Never exceed 40 psi to seat the bead.) Also, the vehicle should not be driven aggressively for at least four hours after tire mounting to allow the lube to dry. GM Goodwrench Rubber Lubricant, p/n 12345884, is the recommended lube for tire mounting. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Diagnostic Procedures Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 1097 Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 1098 condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 1099 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 1100 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 1101 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 1102 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 911713E > Jan > 91 > Tire - Tread Chunking/Torn bead Tires: All Technical Service Bulletins Tire - Tread Chunking/Torn bead Number: 91-171-3E Section: 3E Date: January 1991 Corp. Bulletin No.: 993501R Subject: TIRE DAMAGE CAUSED IN GM ASSEMBLY PLANTS - TREAD CHUNKING TORN BEAD Model and Year: 1988-91 PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-52-3E, DATED OCTOBER 1989. THE 1991 MODEL YEAR HAS BEEN ADDED. ALL COPIES OF 90-52-3E SHOULD BE DISCARDED. Isolated incidents of the following types of tire damage have recently been reported from the field. Any such damage would be present at time of delivery to the dealer. The probable cause of some of this damage has been traced to the assembly plant. Since such tire conditions are usually not the fault of the tire manufacturer, any tires requiring replacement for these reasons should be considered GM's responsibility. Assembly plant damage should not be confused with transportation damage, which continues to be the responsibility of the transportation company. The purpose of this bulletin is to help identify assembly plant tire damage. Tread Chunking This condition is identified by small pieces of tread rubber torn or "chunked" out of the tire. This usually occurs in one area of the tread, although more than one area is possible. The missing tread rubber should be apparent upon visual inspection. It can also usually be detected as a once-per-rev tire noise upon road testing. This condition can happen in the assembly plant during the end of line line roll test. Hard braking such that the tire locks up on the roll could be the cause, although other variables during the roll test can also be factors. Other types of tire tread damage noted at delivery should be considered transportation damage. Torn Bead Rubber This condition is usually not visible unless the tire is dismounted from the wheel and, therefore, may not be detected during new vehicle inspection. Depending on the extent of the tear, the condition may later be detected as a slow air loss, or a slight sidewall bulge. If the tire is dismounted from the wheel and bead rubber is torn, it is possible that this damage occurred in the assembly plant during tire mounting. If it happened in the plant, the tear will usually be on the inboard (blackwall) side of the tire. There should also be evidence of two tears, about 90 degrees apart, although one is usually much Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 911713E > Jan > 91 > Tire - Tread Chunking/Torn bead > Page 1107 more apparent than the other. Both the above described conditions occur very infrequently, with ongoing enhancements underway to reduce their occurance even further. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 931943F > May > 93 > Ignition Lock Cylinder - Replacement Tires: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 931943F > May > 93 > Ignition Lock Cylinder - Replacement > Page 1113 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 931943F > May > 93 > Ignition Lock Cylinder - Replacement > Page 1114 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 931943F > May > 93 > Ignition Lock Cylinder - Replacement > Page 1115 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 931943F > May > 93 > Ignition Lock Cylinder - Replacement > Page 1116 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 931943F > May > 93 > Ignition Lock Cylinder - Replacement > Page 1117 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking Tires: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 1122 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 1131 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 1132 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 1133 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 1138 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 931693E > Apr > 93 > Tires - Slipping on Rim Wheels: Customer Interest Tires - Slipping on Rim Number: 93-169-3E Section: 3E Date: APRIL 1993 Corporate Bulletin No.: 393501 ASE No.: A4 Subject: TIRES SLIPPING ON WHEELS (USE PROPER TIRE MOUNTING PROCEDURE) Model and Year: 1988-93 ALL PASSENGER CARS AND LIGHT DUTY TRUCKS Some incidents of tires slipping (rotating) on wheels have been reported on 1988-93 passenger cars and light duty trucks. Most incidents have occurred when driven aggressively immediately after tire mounting. Hard acceleration and/or braking is usually required. This condition will affect wheel balance, which could result in a vibration. To reduce the chance of tires rotating on their wheels, any excess lube should be wiped from the tire and rim after tire mounting, but before inflating to seat the bead. (Never exceed 40 psi to seat the bead.) Also, the vehicle should not be driven aggressively for at least four hours after tire mounting to allow the lube to dry. GM Goodwrench Rubber Lubricant, p/n 12345884, is the recommended lube for tire mounting. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1148 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1149 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1150 *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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 1155 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1160 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1161 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1166 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1167 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1168 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 1173 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-03-10-102 > Jun > 99 > Warranty - OE Chrome Plated Aluminum Wheel ID Wheels: All Technical Service Bulletins Warranty - OE Chrome Plated Aluminum Wheel ID File In Section: 03 - Suspension Bulletin No.: 99-03-10-102 Date: June, 1999 INFORMATION Subject: Original Equipment Chrome Plated Aluminum Wheel Identification Models: 1999 and Prior Passenger Cars and Light Duty Trucks Chrome plated aluminum wheels have been returned to the Warranty Parts Center that are not the original equipment (OE) components. Original equipment chrome plated aluminum wheels can be identified by either a balance weight clip retention groove (1) or a step (2) that is machined around both of the wheel's rim flanges. The rim flanges (3) of painted original equipment aluminum wheels do not have a groove or a step. Chrome plated aluminum wheels that do not have the wheel rim flange groove or step are aftermarket chrome plated components and are NOT warrantable. Any aftermarket chrome wheels received by the Warranty Parts Center will be charged back to the dealership. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 72-05-05 > Aug > 97 > Warranty - Guidelines for Using E0420 Wheel Replace Wheels: All Technical Service Bulletins Warranty - Guidelines for Using E0420 Wheel Replace File In Section: Warranty Administration Bulletin No.: 72-05-05 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Using EO42O Wheel Replace Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide service personnel with guidelines for using the above subject labor operation. Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Aluminum Wheels (including chrome plated) with Porosity - Wheels that exhibit porosity should be repaired as described in the vehicle service manual. Wheels should not be replaced without wholesale approval. ^ Aluminum Wheels (except chrome plated) with a "Finish Defect" - Wheels that exhibit a defect in the finish, (i.e., discoloration or surface degradation) should be refinished as described in the Corporate Service Bulletin Number 53-17-03A released in May, 1996. ^ Chrome Wheels - Wheels that are chromed and found to have a finish defect can only be replaced. ^ Aluminum and chrome wheels replaced under warranty will be subject to random part review and inspection. Those wheels inspected and found not to be defective and/or should have been repaired, will be subject to charge back. Wheels damaged by normal wear, road hazards, car wash brushes, or other physical or chemical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 531703A > May > 96 > Aluminum Wheels - Refinishing Technical Service Bulletin # 531703A Date: 960501 Aluminum Wheels - Refinishing File In Section: 10 - Body Bulletin No.: 53-17-03A Date: May, 1996 INFORMATION Subject: Aluminum Wheel Refinishing Models: 1991-96 Passenger Cars and Trucks This bulletin is being revised to delete the 1990 model year and add the 1996 model year. Please discard Corporate Bulletin Number 53-17-03 (Section 10 - Body). This bulletin supersedes and cancels all previous service bulletins concerning the refinishing of aluminum wheels. The purpose of this service bulletin is to assist dealerships in repairing the discoloration or surface degradation that has occurred on styled aluminum wheels. This bulletin provides NEW PROCEDURES AND SPECIFIC MATERIALS for the refinishing of painted aluminum wheels or aluminum wheels with discoloration or surface degradation. Important: THE RE-MACHINING OF ALUMINUM WHEELS IS NOT RECOMMENDED. THE RE-CLEAR COATING OF ALUMINUM WHEELS IS NO LONGER RECOMMENDED DUE TO CONCERNS OF REPAIR DURABILITY The new procedure requires the wheel surface be plastic media blasted to remove old paint or clear coat. CHEMICAL STRIPPERS ARE NOT RECOMMENDED. Material Required System 1: DuPont Products 3939-S Cleaning Solvent 615/616 Etching Primer URO 5000 Primer Surfacer IMRON 6000 Basecoat 3440-S IMRON Clear System 2: PPG Products DX533 Aluminum Cleaner DX503 Aluminum Conditioner DP Epoxy Primer Deltron Basecoat (DBC) Concept 2001 Clear Acrylic Urethane System 3: Spies Hecker Permahyd Silicone Remover 7090 Permahyd 1:1 Primer 4070 Permahyd 2:1 Surfacer 5080 Permahyd Base Coat Series 280/285 Permahyd H.S. Clearcoat 8060 Color Selection If the wheels being painted were previously clearcoated aluminum, we would recommend using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option to the customer, you may also use body color. For color Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 531703A > May > 96 > Aluminum Wheels - Refinishing > Page 1190 selection and verification, refer to your paint manufacturer's color book. On wheels that were previous clearcoated aluminum it is recommended that all four wheels and their center caps be refinished to maintain color uniformity. Important: THE PRODUCTS LISTED MUST BE USED AS A SYSTEM. DO NOT MIX OTHER MANUFACTURERS' PRODUCT LINES WITH THE REQUIRED MATERIALS. PRODUCTS LISTED IN THIS BULLETIN HAVE SHOWN THE REQUIRED REPAIR DURABILITY, AND CURRENTLY ARE THE ONLY PAINT SYSTEMS THAT MEET GM SPECIFICATION 4350M-A336. Procedures 1. Remove wheels from vehicle. Tires may remain mounted on wheels. 2. Remove balance weights and mark their location on tire. 3. Wipe excess grease, etc. from wheels with wax and grease remover. 4. Have wheels plastic media blasted to remove clearcoat. FOR FURTHER INFORMATION ON MEDIA BLASTING IN YOUR AREA, CALL US TECHNOLOGIES INC., CONTACT DAVE ROSENBURG AT 1-800-634-9185. Caution: IT IS MANDATORY THAT ADEQUATE RESPIRATORY PROTECTION BE WORN. EXAMPLES OF SUCH PROTECTION ARE: AIR LINE RESPIRATORS WITH FULL HOOD OR HALF MASK. IF NOT AVAILABLE, USE A VAPOR/PARTICULATE RESPIRATOR THAT RESPIRATOR MANUFACTURER RECOMMENDS AS EFFECTIVE FOR ISOCYANATE VAPOR AND MISTS (UNLESS LOCAL REGULATIONS PREVAIL). 5. Painting Process a. Refer to Attachments 1-3 for each System's individual formula and process. b. After following the specific System's individual formula and process, follow these steps: 6. Unmask wheels. 7. Clean all wheel mounting surface of any corrosion, overspray, or dirt. 8. Install new coated balance weights, at marked locations. 9. Replace wheels on vehicle. 10. USE A TORQUE STICK ON AN IMPACT WRENCH, OR A TORQUE WRENCH TO CONSISTENTLY AND UNIFORMLY FASTEN THE WHEEL TO THE SPECIFIED TORQUE FOR THE VEHICLE. THE STAR PATTERN MUST BE FOLLOWED. Important: TORQUE STICKS MUST BE USED ANY TIME AN IMPACT WRENCH IS USED TO TIGHTEN WHEEL NUTS. Warranty Information For vehicles repaired under warranty, use as shown. Attachment 1 - DuPont Products Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 531703A > May > 96 > Aluminum Wheels - Refinishing > Page 1191 Painting Process System: Dupont Products Paint Color Information: Corsican Silver WA EQ9283 Dupont # C9143, Sparkle Silver WA9967 Dupont # C9339 1. Wipe wheel with cleaning solvent: 3939-S, 3949-S or 3900-S. 2. Mask off tires. Important: 3. Mask off all wheel mounting surfaces and wheel mount surfaces. 4. Apply two coats of 615/616-S etching primer to wheel allowing 10 minutes flash between coats. Allow to dry for 30 minutes before applying primer coat. 5. Apply URO 5000 primer 1220/193-S + accelerator 389-S using two coats at 65-70 PSI at the gun. Allow 12-15 minutes between coats. Force bake 30 minutes at 140°F (60°C). 6. Scuff sand using green Scotch-Brite pad. 7. Solvent wipe before top coating. 8. Apply IMRON 6000 base coat to wheel. 2-3 coats to hiding at 60-70 PSI allowing to flash between coats. Base coat needs to dry 20-30 minutes before clearcoat is applied. 9. Apply 3440-S clearcoat to wheel using two coats at 60-70 PSI. Flash 10-15 minutes between coats. 389-S can be used in basecoat and clearcoat to give faster set up times. 10. Allow overnight dry before reassemble. Can be baked for 30 minutes at 140°F (60°C). Attachment 2 - PPG Products Painting Process: PPG System Paint Color Information: Corsican Silver WAEQ9283; PPG # DBC-3531, Sparkle Silver WA9967; PPG # 35367 1. Wash entire wheel with aluminum cleaner DX533, mix 1:3 with water. Allow to react 2-3 minutes and rinse thoroughly. 2. Wash entire wheel with aluminum conditioner DX5O3 straight from the container. Allow to react 2-3 minutes until pale gold or tan color develops. Rinse thoroughly and dry. 3. Mask off tires. Important: 4. Mask off all wheel nut mounting surfaces and wheel mounting surfaces. 5. Apply 1-2 coats of DP Primer and allow to flash for 15-20 minutes. 6. Apply 2-3 coats of Deltron Basecoat (DBC) and allow to flash 20 minutes after the final coat. 7. Apply two (2) wet coats of Concept 2001 Acrylic urethane. 8. Flash 20 minutes and bake 140°F (60°C) for 30 minutes. For more information contact your PPG Jobber. Attachment 3 - Spies Hecker Painting Process: Spies Hecker System Paint Color Information: Corsican Silver AWEQ9283; SH-72913, Sparkle Silver WA9967; SH-71912 1. Clean with Permahyd Silicone Remover 7090. 2. Mask off tires. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 531703A > May > 96 > Aluminum Wheels - Refinishing > Page 1192 Important: 3. Mask off all wheel nut mounting surfaces and wheel mounting surfaces. 4. Apply 1-1/2 coats of Permahyd 1:1 Primer 4070. Mix 1:1 with Permahyd Hardener 3070 as per TDS. 5. Allow to flash for 30 minutes. 6. Apply two (2) coats of Permahyd 2:1 Surfacer 5080. Mix 2:1 with Permahyd Hardener 3071 as per TDS. 7. Bake for 60 minutes at 140°F (60°C) or allow to flash for 3 hours at 68°F (20°C). 8. Apply Permahyd Base Coat Series 280/285 as per TDS. 9. Allow to flash 10 to 15 minutes. 10. Apply 1 to 2 coats of Permacron High Solid Clear Coat 8060 as per TDS. 11. Allow to flash 10 minutes. Then bake at 140°F (60°C) for 40 minutes. For more information, contact your SPIES HECKER Jobber. 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 or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 393504 > Jul > 93 > Wheels - Sealing Leaking Cast Aluminum Wheels: All Technical Service Bulletins Wheels - Sealing Leaking Cast Aluminum Bulletin Number: 93-3-16 Reference Number: 393504 Publish Date: 7/93 Subject: LEAKING CAST ALUMINUM WHEELS (REPAIR WITH ADHESIVE SEALANT) Models Affected: 1985-1993 ALL MODELS Should a vehicle equipped with cast aluminum wheels exhibit a slow leak due to a porous condition existing in the wheel, the wheel can be repaired by using Dow Corning Silastic 732 RTV, p/n 1052366 or equivalent, as described in the following procedure: 1. Remove tire-wheel assembly from vehicle. 2. Locate leaking area by inflating tire to 40 psi and dipping tire-wheel assembly in water bath. 3. If air bubbles are observed, mark leak area and remove tire from wheel. 4. Scuff INSIDE rim surface at leak area with # 80 grit paper and clean area with general purpose cleaner, such as 3M # 08984. 5. Apply 1/8" thick layer of adhesive/sealant to leak area on INSIDE of rim and allow six hours of drying time. 6. Mount tire on wheel, pressurizing to 40 psi and check for leaks. NOTICE: Caution must be used when mounting the tire so as not to damage the sealer. 7. Adjust tire pressure to meet placard specification. 8. Balance tire-wheel assembly, using proper coated weights. 9. Water test wheel again. 10. Reinstall tire-wheel assembly on vehicle. Parts are currently available from GMSPO. WARRANTY INFORMATION: Labor Operation Number: E0420 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 931693E > Apr > 93 > Tires - Slipping on Rim Wheels: All Technical Service Bulletins Tires - Slipping on Rim Number: 93-169-3E Section: 3E Date: APRIL 1993 Corporate Bulletin No.: 393501 ASE No.: A4 Subject: TIRES SLIPPING ON WHEELS (USE PROPER TIRE MOUNTING PROCEDURE) Model and Year: 1988-93 ALL PASSENGER CARS AND LIGHT DUTY TRUCKS Some incidents of tires slipping (rotating) on wheels have been reported on 1988-93 passenger cars and light duty trucks. Most incidents have occurred when driven aggressively immediately after tire mounting. Hard acceleration and/or braking is usually required. This condition will affect wheel balance, which could result in a vibration. To reduce the chance of tires rotating on their wheels, any excess lube should be wiped from the tire and rim after tire mounting, but before inflating to seat the bead. (Never exceed 40 psi to seat the bead.) Also, the vehicle should not be driven aggressively for at least four hours after tire mounting to allow the lube to dry. GM Goodwrench Rubber Lubricant, p/n 12345884, is the recommended lube for tire mounting. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 93203E > Oct > 92 > Aluminum Wheels - Scuff/Scratch Removal Wheels: All Technical Service Bulletins Aluminum Wheels - Scuff/Scratch Removal Number: 93-20-3E Section: 3E Date: OCT. 1992 Corporate Bulletin No.: 010103R ASE No.: A3 Subject: PROCEDURES ON SCUFF/SCRATCH REMOVAL FROM CLEAR COAT ON ALUMINUM WHEELS Model and Year: 1981-85 CITATION 1982-93 CAVALIER 1985-88 MONTE CARLO 1985-90 CELEBRITY 1981-93 CAPRICE, CAMARO AND CORVETTE 1990-93 LUMINA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-321 -3E, DATED AUGUST 1990. THE 1991 -93 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 90-321 -3E SHOULD BE DISCARDED. The clear coat on aluminum wheels can become scuffed and dull if the car is exposed to frequent automatic car washes with aggressive tire brushes. Following are procedures for polishing out minor scuffs and scratches from the clear coat on aluminum wheels. Outlined are three basic procedures which progress from least aggressive (A) to most aggressive (C) depending on the degree of scuffs or scratches in the clear coat. A. Condition - Minor surface scuffs and scratches. Procedure: 1. Clean the wheel surface with soap and water and dry thoroughly. 2. Clean the wheel with 3M general purpose adhesive cleaner, P/N 08984, or equivalent and dry 3. Apply 3M finesse-it finishing material, P/N 05928, or equivalent to the affected area and polish using a 3M superbuff polishing pad, P/N 05705, or equivalent on a low speed polisher (1500-2300 rpm's). 4. Begin with firm pressure on the polisher in the beginning and gradually reduce pressure as the finishing material begins to dry up. 5. Apply a coat of 3M liquid polish, P/N 05939 or 05993, or equivalent to protect the clear coat. B. Condition - More significant scuffs and dulling not removed during procedure A. Procedure: 1. Perform steps 1 and 2 from procedure A. 2. Apply 3M imperial microfinishing compound, P/N 06011, or equivalent and buff with a 3M superbuff compounding pad, P/N 05701, or equivalent on a low speed polisher. A second application may be necessary. 3. Inspect wheel finish. If scuffs and dulling have been removed, proceed to step 4; if not, proceed to procedure C. 4. Finish polishing the wheel with 3M finesse-it finishing material, P/N 05928, or equivalent and a superbuff polishing pad, P/N 05705, or equivalent on a low speed buffer. 5. Apply a coat of 3M liquid polish, P/N O5939 or O5993, or equivalent to protect clear coat. C. Condition - Very significant dulling, scratches, scuffs which have not penetrated through the clear coat. 1. Clean wheel with soap and water and dry. 2. Clean with 3M general purpose adhesive cleaner, P/N 08984, or equivalent. 3. Wet sand the affected area with 3M imperial wet-or-dry paper grade 1500 on a #20 sponge pad, P/N 05526, or equivalent. 4. Occasionally squeegee away the water and check progress. Stop sanding when an even dull appearance is reached. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 93203E > Oct > 92 > Aluminum Wheels - Scuff/Scratch Removal > Page 1205 5. Polish the clear coat to a high gloss using 3M finesse-it finishing material, P/N 05928, or equivalent with a 3M superbuff polishing pad, P/N 05705, or equivalent on a low speed polisher (1500-2300 rpm's). 6. Apply a coat of 3M liquid polish, P/N 05939 or 05993, or equivalent to protect clear coat. NOTE: The following tips will result in an improved appearance when polishing or buffing. ^ Begin with firm pressure and reduce pressure as the polish or compound begins to dry. ^ Do not polish with a dry pad. Use enough material to keep the surface wet. ^ Use extreme caution when polishing or buffing sharp corners or contours to avoid burning the clear coat. Hand rubbing may be necessary. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting Wheels: All Technical Service Bulletins Wheels (Steel) - Damage Due to Improper Mounting Number: 92-232-3E Section: 3E Date: JUNE 1992 Corporate Bulletin No.: 233002 ASE No.: A4 Subject: AVOIDING DAMAGE TO STEEL WHEELS FROM IMPROPER WHEEL/TIRE CHANGING TECHNIQUES Model and Year: 1983-92 ALL PASSENGER CARS AND TRUCKS WITH STEEL WHEELS It is important to use proper procedures to prevent damage to either the tire mounting surface or the wheel mounting holes. Damage can result from the improper wheel attachment or tire mounting techniques on vehicles with steel wheels. 1. IMPROPER TIRE CHANGING TECHNIQUES: It takes about 70 seconds for the air to completely exhaust from a large tire. If the technician doesn't wait this amount of time after removing the valve core, the bead breaker on the tire change could put enough force on the tire to bend the wheel at the mounting surface. Such damage can result in vibration, shimmy, and under severe usage (i.e. police vehicle) lead to cracking. 2. OVER TORQUING OF THE WHEEL NUTS: The service specification for wheel nuts is listed in the Service Manuals. Some wheels have been observed with wheel nuts that were over torqued by as much as 50 percent. This may damage the wheel mounting holes and may also lead to cracks. I. PROPER TIRE CHANGING TECHNIQUES: Completely deflate the tire before attempting to break the tire bead loose. MOUNTING SURFACE CHECKING PROCEDURE Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 1210 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 1211 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 1212 A. Obtain a straight edge approximately 8-9 inches long and, while holding it in two hands, as shown in the attached illustration, place it on the inboard mounting surface of the wheel and try to rock it up and down. B. Repeat the above procedure on three or four different positions on the wheel inboard mounting surface. C. The outer ring of the mounting surface is normally raised above everything inside it. If a wheel mounting surface has been bent on a tire changer, it will be raised above the outer ring and the straight edge will rock on this "raised" portion. D. If a bent wheel is found, it must be replaced. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 1213 II. OVER TORQUING OF WHEEL NUTS: 1. A TORQUE WRENCH MUST BE USED to insure that the wheel nuts are tightened to specification. This should be done in two steps using the star pattern. First, snug the nuts down by hand. Then, using the star pattern and a torque wrench, tighten the wheel nuts to about half the final torque. Finally, tighten the wheel nuts to specification using the star pattern and a torque wrench. 2. NEVER use lubricants or penetrating fluids on wheel studs, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91353E > Aug > 90 > Aluminum Wheels - New Coated Wheel Weights Wheels: All Technical Service Bulletins Aluminum Wheels - New Coated Wheel Weights Number: 91-35-3E Section: 3E Date: August 1990 Corporate Bulletin No.: 003502 Subject: COATED WHEEL WEIGHTS FOR ALUMINUM WHEELS Model and Year: 1985-91 MODELS WITH CAST ALUMINUM WHEELS TO: ALL CHEVROLET DEALERS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 89-65-3E, DATED JANUARY 1989. POLYESTER COATED WHEEL WEIGHTS NOW AVAILABLE FROM GMSPO. THE 1990-91 MODEL YEARS HAVE ALSO BEEN ADDED. ALL COPIES OF 89-65-3E SHOULD BE DISCARDED. Vehicles with cast aluminum wheels use a coated clip on wheel weight. The coating has recently changed from nylon to polyester, giving a more natural appearance that more closely matches the wheel. Coated balance weights are used on both the inboard and outboard rim flanges. They will not discolor, corrode or damage the appearance of the wheel as may have been the case in the past with uncoated clip on weights. These coated weights will fit most GM cast aluminum wheels. There are two types of coated wheel weights available to fit the GM vehicles (see illustration). Both types of weights are available from GMSPO in 1/4 ounce increments. See usage chart below to determine which type weight is correct for the vehicle. "MC" Type Weight Used On: 1990-1991 "W" Car 1988-1990 "Y" Car "AW" Type Weight 1989-1991 "L" Car Used On All Other 1991 "B" Car, "U" Van Series Vehicles 1/4 oz. P/N 9591670 P/N 9591669 1/2 oz. 9591584 9591582 3/4 oz. 9591585 9591583 1-1/4 oz. 9591378 9591362 1-1/2 oz. 9591379 9591363 1-3/4 oz. 9591380 9591364 2 oz. 9591381 9591365 "MC" Type Weight Used On: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91353E > Aug > 90 > Aluminum Wheels - New Coated Wheel Weights > Page 1218 1990-1991 "W" Car 1988-1990 "Y" Car "AW" Type Weight 1989-1991 "L" Car Used On All Other 1991 "B" Car, "U" Van Series Vehicles 2-1/4 oz. 9591382 9591366 2-1/2 oz. 9591383 9591367 3oz. 9591385 9591369 Parts are currently available from GMSPO. Dealers should make sure they have a supply of both types weights for balancing GM aluminum wheels. When installing the coated weights, care must be taken so that the coating does not crack. It is recommended that a Teflon tipped hammer be used, such as 85403 Nicholson Industrial Hammer, their part number CAS 3340551, available through the Charles Strelinger Company, Warren, Mi (313-268-4100), or equivalent. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1228 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1229 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1230 *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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 1235 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1240 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1241 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1246 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1247 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1248 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 1253 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 99-03-10-102 > Jun > 99 > Warranty - OE Chrome Plated Aluminum Wheel ID Wheels: All Technical Service Bulletins Warranty - OE Chrome Plated Aluminum Wheel ID File In Section: 03 - Suspension Bulletin No.: 99-03-10-102 Date: June, 1999 INFORMATION Subject: Original Equipment Chrome Plated Aluminum Wheel Identification Models: 1999 and Prior Passenger Cars and Light Duty Trucks Chrome plated aluminum wheels have been returned to the Warranty Parts Center that are not the original equipment (OE) components. Original equipment chrome plated aluminum wheels can be identified by either a balance weight clip retention groove (1) or a step (2) that is machined around both of the wheel's rim flanges. The rim flanges (3) of painted original equipment aluminum wheels do not have a groove or a step. Chrome plated aluminum wheels that do not have the wheel rim flange groove or step are aftermarket chrome plated components and are NOT warrantable. Any aftermarket chrome wheels received by the Warranty Parts Center will be charged back to the dealership. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 72-05-05 > Aug > 97 > Warranty - Guidelines for Using E0420 Wheel Replace Wheels: All Technical Service Bulletins Warranty - Guidelines for Using E0420 Wheel Replace File In Section: Warranty Administration Bulletin No.: 72-05-05 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Using EO42O Wheel Replace Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide service personnel with guidelines for using the above subject labor operation. Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Aluminum Wheels (including chrome plated) with Porosity - Wheels that exhibit porosity should be repaired as described in the vehicle service manual. Wheels should not be replaced without wholesale approval. ^ Aluminum Wheels (except chrome plated) with a "Finish Defect" - Wheels that exhibit a defect in the finish, (i.e., discoloration or surface degradation) should be refinished as described in the Corporate Service Bulletin Number 53-17-03A released in May, 1996. ^ Chrome Wheels - Wheels that are chromed and found to have a finish defect can only be replaced. ^ Aluminum and chrome wheels replaced under warranty will be subject to random part review and inspection. Those wheels inspected and found not to be defective and/or should have been repaired, will be subject to charge back. Wheels damaged by normal wear, road hazards, car wash brushes, or other physical or chemical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 531703A > May > 96 > Aluminum Wheels - Refinishing Technical Service Bulletin # 531703A Date: 960501 Aluminum Wheels - Refinishing File In Section: 10 - Body Bulletin No.: 53-17-03A Date: May, 1996 INFORMATION Subject: Aluminum Wheel Refinishing Models: 1991-96 Passenger Cars and Trucks This bulletin is being revised to delete the 1990 model year and add the 1996 model year. Please discard Corporate Bulletin Number 53-17-03 (Section 10 - Body). This bulletin supersedes and cancels all previous service bulletins concerning the refinishing of aluminum wheels. The purpose of this service bulletin is to assist dealerships in repairing the discoloration or surface degradation that has occurred on styled aluminum wheels. This bulletin provides NEW PROCEDURES AND SPECIFIC MATERIALS for the refinishing of painted aluminum wheels or aluminum wheels with discoloration or surface degradation. Important: THE RE-MACHINING OF ALUMINUM WHEELS IS NOT RECOMMENDED. THE RE-CLEAR COATING OF ALUMINUM WHEELS IS NO LONGER RECOMMENDED DUE TO CONCERNS OF REPAIR DURABILITY The new procedure requires the wheel surface be plastic media blasted to remove old paint or clear coat. CHEMICAL STRIPPERS ARE NOT RECOMMENDED. Material Required System 1: DuPont Products 3939-S Cleaning Solvent 615/616 Etching Primer URO 5000 Primer Surfacer IMRON 6000 Basecoat 3440-S IMRON Clear System 2: PPG Products DX533 Aluminum Cleaner DX503 Aluminum Conditioner DP Epoxy Primer Deltron Basecoat (DBC) Concept 2001 Clear Acrylic Urethane System 3: Spies Hecker Permahyd Silicone Remover 7090 Permahyd 1:1 Primer 4070 Permahyd 2:1 Surfacer 5080 Permahyd Base Coat Series 280/285 Permahyd H.S. Clearcoat 8060 Color Selection If the wheels being painted were previously clearcoated aluminum, we would recommend using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option to the customer, you may also use body color. For color Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 531703A > May > 96 > Aluminum Wheels - Refinishing > Page 1270 selection and verification, refer to your paint manufacturer's color book. On wheels that were previous clearcoated aluminum it is recommended that all four wheels and their center caps be refinished to maintain color uniformity. Important: THE PRODUCTS LISTED MUST BE USED AS A SYSTEM. DO NOT MIX OTHER MANUFACTURERS' PRODUCT LINES WITH THE REQUIRED MATERIALS. PRODUCTS LISTED IN THIS BULLETIN HAVE SHOWN THE REQUIRED REPAIR DURABILITY, AND CURRENTLY ARE THE ONLY PAINT SYSTEMS THAT MEET GM SPECIFICATION 4350M-A336. Procedures 1. Remove wheels from vehicle. Tires may remain mounted on wheels. 2. Remove balance weights and mark their location on tire. 3. Wipe excess grease, etc. from wheels with wax and grease remover. 4. Have wheels plastic media blasted to remove clearcoat. FOR FURTHER INFORMATION ON MEDIA BLASTING IN YOUR AREA, CALL US TECHNOLOGIES INC., CONTACT DAVE ROSENBURG AT 1-800-634-9185. Caution: IT IS MANDATORY THAT ADEQUATE RESPIRATORY PROTECTION BE WORN. EXAMPLES OF SUCH PROTECTION ARE: AIR LINE RESPIRATORS WITH FULL HOOD OR HALF MASK. IF NOT AVAILABLE, USE A VAPOR/PARTICULATE RESPIRATOR THAT RESPIRATOR MANUFACTURER RECOMMENDS AS EFFECTIVE FOR ISOCYANATE VAPOR AND MISTS (UNLESS LOCAL REGULATIONS PREVAIL). 5. Painting Process a. Refer to Attachments 1-3 for each System's individual formula and process. b. After following the specific System's individual formula and process, follow these steps: 6. Unmask wheels. 7. Clean all wheel mounting surface of any corrosion, overspray, or dirt. 8. Install new coated balance weights, at marked locations. 9. Replace wheels on vehicle. 10. USE A TORQUE STICK ON AN IMPACT WRENCH, OR A TORQUE WRENCH TO CONSISTENTLY AND UNIFORMLY FASTEN THE WHEEL TO THE SPECIFIED TORQUE FOR THE VEHICLE. THE STAR PATTERN MUST BE FOLLOWED. Important: TORQUE STICKS MUST BE USED ANY TIME AN IMPACT WRENCH IS USED TO TIGHTEN WHEEL NUTS. Warranty Information For vehicles repaired under warranty, use as shown. Attachment 1 - DuPont Products Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 531703A > May > 96 > Aluminum Wheels - Refinishing > Page 1271 Painting Process System: Dupont Products Paint Color Information: Corsican Silver WA EQ9283 Dupont # C9143, Sparkle Silver WA9967 Dupont # C9339 1. Wipe wheel with cleaning solvent: 3939-S, 3949-S or 3900-S. 2. Mask off tires. Important: 3. Mask off all wheel mounting surfaces and wheel mount surfaces. 4. Apply two coats of 615/616-S etching primer to wheel allowing 10 minutes flash between coats. Allow to dry for 30 minutes before applying primer coat. 5. Apply URO 5000 primer 1220/193-S + accelerator 389-S using two coats at 65-70 PSI at the gun. Allow 12-15 minutes between coats. Force bake 30 minutes at 140°F (60°C). 6. Scuff sand using green Scotch-Brite pad. 7. Solvent wipe before top coating. 8. Apply IMRON 6000 base coat to wheel. 2-3 coats to hiding at 60-70 PSI allowing to flash between coats. Base coat needs to dry 20-30 minutes before clearcoat is applied. 9. Apply 3440-S clearcoat to wheel using two coats at 60-70 PSI. Flash 10-15 minutes between coats. 389-S can be used in basecoat and clearcoat to give faster set up times. 10. Allow overnight dry before reassemble. Can be baked for 30 minutes at 140°F (60°C). Attachment 2 - PPG Products Painting Process: PPG System Paint Color Information: Corsican Silver WAEQ9283; PPG # DBC-3531, Sparkle Silver WA9967; PPG # 35367 1. Wash entire wheel with aluminum cleaner DX533, mix 1:3 with water. Allow to react 2-3 minutes and rinse thoroughly. 2. Wash entire wheel with aluminum conditioner DX5O3 straight from the container. Allow to react 2-3 minutes until pale gold or tan color develops. Rinse thoroughly and dry. 3. Mask off tires. Important: 4. Mask off all wheel nut mounting surfaces and wheel mounting surfaces. 5. Apply 1-2 coats of DP Primer and allow to flash for 15-20 minutes. 6. Apply 2-3 coats of Deltron Basecoat (DBC) and allow to flash 20 minutes after the final coat. 7. Apply two (2) wet coats of Concept 2001 Acrylic urethane. 8. Flash 20 minutes and bake 140°F (60°C) for 30 minutes. For more information contact your PPG Jobber. Attachment 3 - Spies Hecker Painting Process: Spies Hecker System Paint Color Information: Corsican Silver AWEQ9283; SH-72913, Sparkle Silver WA9967; SH-71912 1. Clean with Permahyd Silicone Remover 7090. 2. Mask off tires. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 531703A > May > 96 > Aluminum Wheels - Refinishing > Page 1272 Important: 3. Mask off all wheel nut mounting surfaces and wheel mounting surfaces. 4. Apply 1-1/2 coats of Permahyd 1:1 Primer 4070. Mix 1:1 with Permahyd Hardener 3070 as per TDS. 5. Allow to flash for 30 minutes. 6. Apply two (2) coats of Permahyd 2:1 Surfacer 5080. Mix 2:1 with Permahyd Hardener 3071 as per TDS. 7. Bake for 60 minutes at 140°F (60°C) or allow to flash for 3 hours at 68°F (20°C). 8. Apply Permahyd Base Coat Series 280/285 as per TDS. 9. Allow to flash 10 to 15 minutes. 10. Apply 1 to 2 coats of Permacron High Solid Clear Coat 8060 as per TDS. 11. Allow to flash 10 minutes. Then bake at 140°F (60°C) for 40 minutes. For more information, contact your SPIES HECKER Jobber. 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 or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 393504 > Jul > 93 > Wheels - Sealing Leaking Cast Aluminum Wheels: All Technical Service Bulletins Wheels - Sealing Leaking Cast Aluminum Bulletin Number: 93-3-16 Reference Number: 393504 Publish Date: 7/93 Subject: LEAKING CAST ALUMINUM WHEELS (REPAIR WITH ADHESIVE SEALANT) Models Affected: 1985-1993 ALL MODELS Should a vehicle equipped with cast aluminum wheels exhibit a slow leak due to a porous condition existing in the wheel, the wheel can be repaired by using Dow Corning Silastic 732 RTV, p/n 1052366 or equivalent, as described in the following procedure: 1. Remove tire-wheel assembly from vehicle. 2. Locate leaking area by inflating tire to 40 psi and dipping tire-wheel assembly in water bath. 3. If air bubbles are observed, mark leak area and remove tire from wheel. 4. Scuff INSIDE rim surface at leak area with # 80 grit paper and clean area with general purpose cleaner, such as 3M # 08984. 5. Apply 1/8" thick layer of adhesive/sealant to leak area on INSIDE of rim and allow six hours of drying time. 6. Mount tire on wheel, pressurizing to 40 psi and check for leaks. NOTICE: Caution must be used when mounting the tire so as not to damage the sealer. 7. Adjust tire pressure to meet placard specification. 8. Balance tire-wheel assembly, using proper coated weights. 9. Water test wheel again. 10. Reinstall tire-wheel assembly on vehicle. Parts are currently available from GMSPO. WARRANTY INFORMATION: Labor Operation Number: E0420 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 931693E > Apr > 93 > Tires - Slipping on Rim Wheels: All Technical Service Bulletins Tires - Slipping on Rim Number: 93-169-3E Section: 3E Date: APRIL 1993 Corporate Bulletin No.: 393501 ASE No.: A4 Subject: TIRES SLIPPING ON WHEELS (USE PROPER TIRE MOUNTING PROCEDURE) Model and Year: 1988-93 ALL PASSENGER CARS AND LIGHT DUTY TRUCKS Some incidents of tires slipping (rotating) on wheels have been reported on 1988-93 passenger cars and light duty trucks. Most incidents have occurred when driven aggressively immediately after tire mounting. Hard acceleration and/or braking is usually required. This condition will affect wheel balance, which could result in a vibration. To reduce the chance of tires rotating on their wheels, any excess lube should be wiped from the tire and rim after tire mounting, but before inflating to seat the bead. (Never exceed 40 psi to seat the bead.) Also, the vehicle should not be driven aggressively for at least four hours after tire mounting to allow the lube to dry. GM Goodwrench Rubber Lubricant, p/n 12345884, is the recommended lube for tire mounting. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 93203E > Oct > 92 > Aluminum Wheels - Scuff/Scratch Removal Wheels: All Technical Service Bulletins Aluminum Wheels - Scuff/Scratch Removal Number: 93-20-3E Section: 3E Date: OCT. 1992 Corporate Bulletin No.: 010103R ASE No.: A3 Subject: PROCEDURES ON SCUFF/SCRATCH REMOVAL FROM CLEAR COAT ON ALUMINUM WHEELS Model and Year: 1981-85 CITATION 1982-93 CAVALIER 1985-88 MONTE CARLO 1985-90 CELEBRITY 1981-93 CAPRICE, CAMARO AND CORVETTE 1990-93 LUMINA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-321 -3E, DATED AUGUST 1990. THE 1991 -93 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 90-321 -3E SHOULD BE DISCARDED. The clear coat on aluminum wheels can become scuffed and dull if the car is exposed to frequent automatic car washes with aggressive tire brushes. Following are procedures for polishing out minor scuffs and scratches from the clear coat on aluminum wheels. Outlined are three basic procedures which progress from least aggressive (A) to most aggressive (C) depending on the degree of scuffs or scratches in the clear coat. A. Condition - Minor surface scuffs and scratches. Procedure: 1. Clean the wheel surface with soap and water and dry thoroughly. 2. Clean the wheel with 3M general purpose adhesive cleaner, P/N 08984, or equivalent and dry 3. Apply 3M finesse-it finishing material, P/N 05928, or equivalent to the affected area and polish using a 3M superbuff polishing pad, P/N 05705, or equivalent on a low speed polisher (1500-2300 rpm's). 4. Begin with firm pressure on the polisher in the beginning and gradually reduce pressure as the finishing material begins to dry up. 5. Apply a coat of 3M liquid polish, P/N 05939 or 05993, or equivalent to protect the clear coat. B. Condition - More significant scuffs and dulling not removed during procedure A. Procedure: 1. Perform steps 1 and 2 from procedure A. 2. Apply 3M imperial microfinishing compound, P/N 06011, or equivalent and buff with a 3M superbuff compounding pad, P/N 05701, or equivalent on a low speed polisher. A second application may be necessary. 3. Inspect wheel finish. If scuffs and dulling have been removed, proceed to step 4; if not, proceed to procedure C. 4. Finish polishing the wheel with 3M finesse-it finishing material, P/N 05928, or equivalent and a superbuff polishing pad, P/N 05705, or equivalent on a low speed buffer. 5. Apply a coat of 3M liquid polish, P/N O5939 or O5993, or equivalent to protect clear coat. C. Condition - Very significant dulling, scratches, scuffs which have not penetrated through the clear coat. 1. Clean wheel with soap and water and dry. 2. Clean with 3M general purpose adhesive cleaner, P/N 08984, or equivalent. 3. Wet sand the affected area with 3M imperial wet-or-dry paper grade 1500 on a #20 sponge pad, P/N 05526, or equivalent. 4. Occasionally squeegee away the water and check progress. Stop sanding when an even dull appearance is reached. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 93203E > Oct > 92 > Aluminum Wheels - Scuff/Scratch Removal > Page 1285 5. Polish the clear coat to a high gloss using 3M finesse-it finishing material, P/N 05928, or equivalent with a 3M superbuff polishing pad, P/N 05705, or equivalent on a low speed polisher (1500-2300 rpm's). 6. Apply a coat of 3M liquid polish, P/N 05939 or 05993, or equivalent to protect clear coat. NOTE: The following tips will result in an improved appearance when polishing or buffing. ^ Begin with firm pressure and reduce pressure as the polish or compound begins to dry. ^ Do not polish with a dry pad. Use enough material to keep the surface wet. ^ Use extreme caution when polishing or buffing sharp corners or contours to avoid burning the clear coat. Hand rubbing may be necessary. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting Wheels: All Technical Service Bulletins Wheels (Steel) - Damage Due to Improper Mounting Number: 92-232-3E Section: 3E Date: JUNE 1992 Corporate Bulletin No.: 233002 ASE No.: A4 Subject: AVOIDING DAMAGE TO STEEL WHEELS FROM IMPROPER WHEEL/TIRE CHANGING TECHNIQUES Model and Year: 1983-92 ALL PASSENGER CARS AND TRUCKS WITH STEEL WHEELS It is important to use proper procedures to prevent damage to either the tire mounting surface or the wheel mounting holes. Damage can result from the improper wheel attachment or tire mounting techniques on vehicles with steel wheels. 1. IMPROPER TIRE CHANGING TECHNIQUES: It takes about 70 seconds for the air to completely exhaust from a large tire. If the technician doesn't wait this amount of time after removing the valve core, the bead breaker on the tire change could put enough force on the tire to bend the wheel at the mounting surface. Such damage can result in vibration, shimmy, and under severe usage (i.e. police vehicle) lead to cracking. 2. OVER TORQUING OF THE WHEEL NUTS: The service specification for wheel nuts is listed in the Service Manuals. Some wheels have been observed with wheel nuts that were over torqued by as much as 50 percent. This may damage the wheel mounting holes and may also lead to cracks. I. PROPER TIRE CHANGING TECHNIQUES: Completely deflate the tire before attempting to break the tire bead loose. MOUNTING SURFACE CHECKING PROCEDURE Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 1290 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 1291 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 1292 A. Obtain a straight edge approximately 8-9 inches long and, while holding it in two hands, as shown in the attached illustration, place it on the inboard mounting surface of the wheel and try to rock it up and down. B. Repeat the above procedure on three or four different positions on the wheel inboard mounting surface. C. The outer ring of the mounting surface is normally raised above everything inside it. If a wheel mounting surface has been bent on a tire changer, it will be raised above the outer ring and the straight edge will rock on this "raised" portion. D. If a bent wheel is found, it must be replaced. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 1293 II. OVER TORQUING OF WHEEL NUTS: 1. A TORQUE WRENCH MUST BE USED to insure that the wheel nuts are tightened to specification. This should be done in two steps using the star pattern. First, snug the nuts down by hand. Then, using the star pattern and a torque wrench, tighten the wheel nuts to about half the final torque. Finally, tighten the wheel nuts to specification using the star pattern and a torque wrench. 2. NEVER use lubricants or penetrating fluids on wheel studs, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 91353E > Aug > 90 > Aluminum Wheels - New Coated Wheel Weights Wheels: All Technical Service Bulletins Aluminum Wheels - New Coated Wheel Weights Number: 91-35-3E Section: 3E Date: August 1990 Corporate Bulletin No.: 003502 Subject: COATED WHEEL WEIGHTS FOR ALUMINUM WHEELS Model and Year: 1985-91 MODELS WITH CAST ALUMINUM WHEELS TO: ALL CHEVROLET DEALERS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 89-65-3E, DATED JANUARY 1989. POLYESTER COATED WHEEL WEIGHTS NOW AVAILABLE FROM GMSPO. THE 1990-91 MODEL YEARS HAVE ALSO BEEN ADDED. ALL COPIES OF 89-65-3E SHOULD BE DISCARDED. Vehicles with cast aluminum wheels use a coated clip on wheel weight. The coating has recently changed from nylon to polyester, giving a more natural appearance that more closely matches the wheel. Coated balance weights are used on both the inboard and outboard rim flanges. They will not discolor, corrode or damage the appearance of the wheel as may have been the case in the past with uncoated clip on weights. These coated weights will fit most GM cast aluminum wheels. There are two types of coated wheel weights available to fit the GM vehicles (see illustration). Both types of weights are available from GMSPO in 1/4 ounce increments. See usage chart below to determine which type weight is correct for the vehicle. "MC" Type Weight Used On: 1990-1991 "W" Car 1988-1990 "Y" Car "AW" Type Weight 1989-1991 "L" Car Used On All Other 1991 "B" Car, "U" Van Series Vehicles 1/4 oz. P/N 9591670 P/N 9591669 1/2 oz. 9591584 9591582 3/4 oz. 9591585 9591583 1-1/4 oz. 9591378 9591362 1-1/2 oz. 9591379 9591363 1-3/4 oz. 9591380 9591364 2 oz. 9591381 9591365 "MC" Type Weight Used On: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > All Technical Service Bulletins for Wheels: > 91353E > Aug > 90 > Aluminum Wheels - New Coated Wheel Weights > Page 1298 1990-1991 "W" Car 1988-1990 "Y" Car "AW" Type Weight 1989-1991 "L" Car Used On All Other 1991 "B" Car, "U" Van Series Vehicles 2-1/4 oz. 9591382 9591366 2-1/2 oz. 9591383 9591367 3oz. 9591385 9591369 Parts are currently available from GMSPO. Dealers should make sure they have a supply of both types weights for balancing GM aluminum wheels. When installing the coated weights, care must be taken so that the coating does not crack. It is recommended that a Teflon tipped hammer be used, such as 85403 Nicholson Industrial Hammer, their part number CAS 3340551, available through the Charles Strelinger Company, Warren, Mi (313-268-4100), or equivalent. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 9313310 > Mar > 93 > Door Locks - Binding or Sticking or Key Hard to Insert Door Lock Cylinder: All Technical Service Bulletins Door Locks - Binding or Sticking or Key Hard to Insert Number: 93-133-10 Section: 10 Date: MARCH 1993 Corporate Bulletin No.: 1341070R ASE No.: B1 Subject: DOOR LOCK CYLINDERS (RECOMMENDED LUBRICATION) Model and Year: ALL 1993 AND PREVIOUS MODEL CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN 92-41-10, DATED NOV. 1991. THE 1993 MODEL YEAR HAS BEEN ADDED AS WELL AS A NOTE. PLEASE DISCARD ALL COPIES OF 92-41-10. Customer comments of binding/sticking door lock cylinders, or keys that are hard to insert or extract may be corrected in many cases by applying the proper lubrication. The recommended materials for lubricating these components are (in order of preference): - GM # 12345120 Multi purpose lubricant (9 oz. spray) or # 12345121 (12 oz.). - 5 W 30 Motor Oil - GM # 1052276 or 1052277 spray type Silicone (4.5 oz. or 12 oz. cans). Penetrating oil type lubricants (such as GM # 1052949 or 1052950, WD-40 lubricants) ARE NOT RECOMMENDED because they wash out the original lubrication and eventually evaporate, leaving little or no lubricating material. However, if these type materials are used to "unfreeze" or loosen lock cylinder components, refer to steps 2 through 4 listed below for the proper methods of lubricating. NOTE: DO NOT REPLACE THE DOOR LOCK CYLINDERS UNTIL AFTER THE LUBRICATING MATERIALS HAVE BEEN USED AND THE CYLINDER REMAINS FROZEN/BOUND. If door lock cylinders require replacement for any reason, apply a coating of GM # 12345120 Multi purpose Lubricant to the inside of the lock case and the cylinder keyway prior to assembling and installing the cylinder. Parts are currently available from GMSPO. Frozen cylinders due to cold weather may be repaired using the following procedure: 1. Apply heat to the cylinder area with a heat gun while being careful not to damage the painted surfaces. 2. Hold the shutter door open with a paper clip (or similar item) and force air into the cylinder using compressed air and a blow gun attachment. 3. While holding the shutter door open, inject a small amount of lubricant (see above recommendations) into the cylinder. 4. Work the key into the cylinder several times and wipe any excess lubrication residue from the key. Use applicable Labor Time Number and Time allowance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing Removal and Installation Wheel Bearing: Service and Repair Front Wheel Bearing Removal and Installation FRONT WHEEL BEARINGS AND/OR HUB Fig. 2 Modified Outer Seal Protector Fig. 3 Removing And Installing Shaft Nut REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly, then install modified outer seal protector No. J 34754 or equivalent, Fig. 2. 3. Insert a drift punch through the rotor, Fig. 3, then remove axle shaft nut and washer. 4. On 1989-90 models, using a plastic or rubber mallet, strike end of axle shaft to disengage axle from hub and bearing. Shaft nut can be partially installed to protect threads. 5. On 1991-92 models, remove ball joint, then using tool No. J 28733-A or equivalent, disengage axle from hub and bearing assembly. 6. On all models, move axle shaft inward, then remove caliper attaching bolts and support caliper. 7. Remove brake rotor, then hub and bearing assembly attaching bolts. 8. Remove hub and bearing assembly. 9. Reverse to install. Torque attaching bolts to specifications. INSTALLATION 1. Install hub and bearing assembly, torque attaching bolts to specification. 2. Install hub and bearing seal, then the brake rotor. 3. Install caliper, torque attaching bolts to specification. 4. Move axle shaft outward, then insert drift punch through rotor, Fig. 3. 5. Install washer and new shaft nut, torque shaft nut to specification. 6. On 1991-92 models, install ball joint. 7. On all models, remove drift punch and seal protector. 8. Install tire and wheel assembly, then lower vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing Removal and Installation > Page 1308 Wheel Bearing: Service and Repair Rear Suspension REAR HUB AND/OR BEARINGS 1. Raise and support vehicle, then remove wheel and tire assembly and brake drum. Do not hammer brake drum since damage to bearing may result. 2. Remove four hub/bearing assembly to rear axle attaching bolts, then the hub/bearing assembly from axle. The upper rear hub attaching bolt may not clear brake shoe when removing hub and bearing assembly. Partially remove hub and bearing assembly prior to removing this bolt. 3. Reverse procedure to install. Torque hub attaching bolts to specification. Use care not to drop hub/bearing assembly since damage to bearing may result. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 914143E > Sep > 91 > Wheel Center Caps - Rattling Noise Wheel Cover: Customer Interest Wheel Center Caps - Rattling Noise Number: 91-414-3E Section: 3E Date: SEPT. 1991 Corporate Bulletin No.: 133503 ASE No.: A2, A3, A4, A5, B1 Subject: RATTLE NOISE AS A RESULT OF LOOSE WHEEL CENTER CAPS Model and Year: 1991 CAVALIER WITH Z24 TRIM PACKAGE Condition: Some 1991 "J" cars with the Z24 trim package may exhibit a rattling noise due to the wheel center hub cap being loose. Cause: Loose fit between the wheel and wheel center cap caused by oversize diameter in wheel. Correction: Using channel-lock pliers, with a cloth on cap face to protect the disc from damage, rework the center cap wire retaining ring (as shown in the picture) in five places to provide a tight fit of the cap to the improperly machined wheels. Bend the wire ring toward the cap disc as shown to obtain a permanent set of approximately one (1) wire diameter. This condition effects all 1991 Chevrolet J cars with Z24 from 1991 start of production through VIN breakpoint M7194096. Labor Operation Number: T1761 Labor Time: 0.2 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 914143E > Sep > 91 > Wheel Center Caps - Rattling Noise > Page 1317 Add Time: 0.2 (one or all) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 914143E > Sep > 91 > Wheel Center Caps - Rattling Noise Wheel Cover: All Technical Service Bulletins Wheel Center Caps - Rattling Noise Number: 91-414-3E Section: 3E Date: SEPT. 1991 Corporate Bulletin No.: 133503 ASE No.: A2, A3, A4, A5, B1 Subject: RATTLE NOISE AS A RESULT OF LOOSE WHEEL CENTER CAPS Model and Year: 1991 CAVALIER WITH Z24 TRIM PACKAGE Condition: Some 1991 "J" cars with the Z24 trim package may exhibit a rattling noise due to the wheel center hub cap being loose. Cause: Loose fit between the wheel and wheel center cap caused by oversize diameter in wheel. Correction: Using channel-lock pliers, with a cloth on cap face to protect the disc from damage, rework the center cap wire retaining ring (as shown in the picture) in five places to provide a tight fit of the cap to the improperly machined wheels. Bend the wire ring toward the cap disc as shown to obtain a permanent set of approximately one (1) wire diameter. This condition effects all 1991 Chevrolet J cars with Z24 from 1991 start of production through VIN breakpoint M7194096. Labor Operation Number: T1761 Labor Time: 0.2 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 914143E > Sep > 91 > Wheel Center Caps - Rattling Noise > Page 1323 Add Time: 0.2 (one or all) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut Torque 183 - 192 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Lug Nut Torque Patterns IMPORTANT Check all parts, including rims, lug studs, lug nuts, and mating surfaces of hubs and tire rims for rust, damage, or dirt. Clean mating surfaces with a wire brush to remove any foriegn material. Replace any damaged parts as needed. Careless installation of tire/rim assemblies in a vehicle is a major cause of tire installation problems. Proper installation, including fastener torque, is essential to economical, safe and trouble free service. Use only the proper sizes and types of fasteners for safe and proper service. Tighten the fasteners a quarter turn at a time using the tightening sequence diagram as a guide. This is very important to prevent misalignment of the wheel. Continue tightening the fasteners in sequence until the fasteners are tightened to the proper torque (See WHEEL FASTENER TORQUE). CAUTION: Improper torque or tightening sequence can cause distortion, fatigue cracks, or alignment problems. After driving the vehicle for a short distance, recheck the wheel fastener torque. Parts will usually seat naturally, reducing the torque on the fasteners. Retorque all fasteners to the proper torque. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70% of the highest and no cylinder reading should be less than 689 kPa (100 psi). Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair Camshaft Gear/Sprocket: Service and Repair Fig.11 Timing Chain & Sprockets Timing Chain Tensioner 1. Disconnect battery ground cable, then remove crankcase front cover as described in CRANKCASE FRONT COVER. 2. Align marks on crankshaft sprocket and camshaft sprocket, Fig. 11. 3. Remove timing chain tensioner upper bolt, then loosen timing chain tensioner Torx as far as possible, but do not remove. 4. Remove camshaft sprocket and timing chain. 5. Using puller tool No. J 22888 on 1990 models, tool No. J 22888-20 on 1991 models or equivalents, remove crankshaft sprocket. 6. Reverse procedure to install, noting the following: a. Compress tensioner spring, then install a cotter pin or nail into hole A as shown in Fig. 12. b. Lube timing chain and sprockets with engine oil, lube thrust thrust surface with camshaft assembly lube No. 1052365 or equivalent. c. Align marks on camshaft and crankshaft sprockets with tabs on tensioner as shown in Fig. 12. d. Align dowel in camshaft with dowel hole camshaft sprocket. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Page 1340 e. Draw camshaft sprocket onto camshaft using the mounting bolt. Torque to specifications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Vin G, Camshaft Dimensions Vin G, Camshaft Dimensions Camshaft Journal Diameter 1.867-1.869 in Camshaft Bearing Clearance 0.0010-0.0039 in Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1344 Camshaft: Service and Repair REMOVAL 1. Remove engine assembly as described in ENGINE. 2. Drain engine oil and remove oil filter. 3. Remove valve lifters and crankcase front cover as described previously. 4. Remove oil pump drive, then remove timing chain and camshaft sprocket. 5. Remove camshaft thrust plate and camshaft. Use care not to damage camshaft bearings with the camshaft when withdrawing the camshaft. 6. Inspect camshaft for wear, galling, gouges and overheating. If any of these problems exist, replace the camshaft. INSTALLATION 1. Install camshaft and thrust plate. Coat camshaft lobes and bearings with camshaft lube No. 1051396 or equivalent. Insert camshaft with extreme care to avoid personal injury and gouging of the camshaft bearings. 2. Torque thrust plate to specifications, then install camshaft sprocket and timing chain. 3. Install crankcase front cover. 4. Replace valve lifters. Lifters must be installed in the same bores from which they were removed. If a new camshaft is installed, replace all valve lifters. Some lifters may be oversized, verify marking near the lifter bore. 5. Install valve mechanism, parts must be reinstalled in the same position and with the same mating surfaces from which they were removed. 6. Install rocker cover, then the oil pump drive. 7. Replace oil filter, then install engine assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair 1. Remove rocker cover as described previously. 2. Loosen rocker arm nut and swing rocker arm aside. 3. Remove pushrod, then using a flexible magnetic wand remove lifter. 4. Inspect lifter for any signs of damage or wear, replacing as necessary. 5. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair Push Rod: Service and Repair ROCKER ARM AND push rod Fig. 7 Rocker Arm Cover, Rocker Arms & Pushrod Replacement (Figure 1) Roller Lifter And Anti-rotation Bracket Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 1351 IMPORTANT ^ Place components in a rack in order of disassembly so they can be reinstalled at the same ocation and with the same mating surface as when removed. 1. Negative battery cable. 2. Valve rocker arm cover. 3. Rocker arm nut. 4. Rocker arm and ball. 5. Push rod. INSTALL OR CONNECT ^ Whenever new rocker arms and/or rocker arm balls are being installed, coat bearing surfaces of rocker arms and rocker arm balls with camshaft assembly lube GM P/N 1052365 or equivalent. 1. Push rods, making sure they seat in lifters. 2. Rocker arm and ball. 3. Apply Dri-Slide Molly lubricant GM P/N 1052948 or equivalent to threads of stud. 4. Rocker arm nuts. TIGHTEN ^ Nuts to 30 Nm (22 lbs. ft.). 5. Valve rocker arm cover. 6. Negative battery cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Rocker Arm Nut Torque Rocker Arm Assembly: Specifications Rocker Arm Nut Torque ROCKER ARM TORQUE Fig. 7 Rocker Arm Cover, Rocker Arms & Pushrod Replacement ^ Rocker Arms are not adjustable on this engine, tighten Rocker Arm Nuts to 30 Nm (22 lbs. ft.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Rocker Arm Nut Torque > Page 1356 Rocker Arm Assembly: Specifications Rocker Arm Stud Torque The OEM service manual does not provide a specification for this component. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1357 Rocker Arm Assembly: Adjustments ROCKER ARM ADJUSTMENT Fig. 7 Rocker Arm Cover, Rocker Arms & Pushrod Replacement ^ Rocker Arms are not adjustable on this engine, tighten Rocker Arm Nuts to 30 Nm (22 lbs. ft.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1358 Rocker Arm Assembly: Service and Repair ROCKER ARM AND push rod Fig. 7 Rocker Arm Cover, Rocker Arms & Pushrod Replacement (Figure 1) Roller Lifter And Anti-rotation Bracket Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1359 IMPORTANT ^ Place components in a rack in order of disassembly so they can be reinstalled at the same ocation and with the same mating surface as when removed. 1. Negative battery cable. 2. Valve rocker arm cover. 3. Rocker arm nut. 4. Rocker arm and ball. 5. Push rod. INSTALL OR CONNECT ^ Whenever new rocker arms and/or rocker arm balls are being installed, coat bearing surfaces of rocker arms and rocker arm balls with camshaft assembly lube GM P/N 1052365 or equivalent. 1. Push rods, making sure they seat in lifters. 2. Rocker arm and ball. 3. Apply Dri-Slide Molly lubricant GM P/N 1052948 or equivalent to threads of stud. 4. Rocker arm nuts. TIGHTEN ^ Nuts to 30 Nm (22 lbs. ft.). 5. Valve rocker arm cover. 6. Negative battery cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bearing Clearance Connecting Rod: Specifications Vin G, Clearance Value Vin G, Clearance Value Side Clearance 0.0039-0.0149 in Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bearing Clearance > Page 1365 Connecting Rod: Specifications Torque Specifications 38 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair Crankshaft Gear/Sprocket: Service and Repair Fig.11 Timing Chain & Sprockets Timing Chain Tensioner 1. Disconnect battery ground cable, then remove crankcase front cover as described in CRANKCASE FRONT COVER. 2. Align marks on crankshaft sprocket and camshaft sprocket, Fig. 11. 3. Remove timing chain tensioner upper bolt, then loosen timing chain tensioner Torx as far as possible, but do not remove. 4. Remove camshaft sprocket and timing chain. 5. Using puller tool No. J 22888 on 1990 models, tool No. J 22888-20 on 1991 models or equivalents, remove crankshaft sprocket. 6. Reverse procedure to install, noting the following: a. Compress tensioner spring, then install a cotter pin or nail into hole A as shown in Fig. 12. b. Lube timing chain and sprockets with engine oil, lube thrust thrust surface with camshaft assembly lube No. 1052365 or equivalent. c. Align marks on camshaft and crankshaft sprockets with tabs on tensioner as shown in Fig. 12. d. Align dowel in camshaft with dowel hole camshaft sprocket. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Page 1369 e. Draw camshaft sprocket onto camshaft using the mounting bolt. Torque to specifications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Main Bearing Torque Specifications Crankshaft: Specifications Main Bearing Caps Main Bearing Caps Torque Specifications 70 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Main Bearing Torque Specifications > Page 1374 Crankshaft: Specifications Vin G, Crankshaft Dimensions Vin G, Crankshaft Dimensions Standard Journal Diameter Main Bearing 2.4945-2.4954 in Crank Pin 1.9983-1.9994 in Out of Round All 0.0002 in Note: Maximum Taper All 0.0002 in Note: Maximum Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Main Bearing Torque Specifications > Page 1375 Crankshaft: Specifications Vin G, Clearance Values Vin G, Clearance Values Main Bearings 0.0006-0.0019 in Connecting Rod Bearings 0.0010-0.0031 in Thrust Bearing Clearance 0.002-0.007 in Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair Harmonic Balancer - Crankshaft Pulley: Service and Repair Fig. 10 Exploded View Of Cylinder Block Assembly REMOVAL Refer to Fig. 10, when performing the following any procedures. 1. Disconnect battery ground cable. 2. Remove serpentine belt, then raise and support vehicle. 3. Remove wheel and tire assembly, then inner fender splash shield. 4. Remove three crankshaft pulley retaining bolts. 5. Remove crankshaft pulley hub bolt, then the crankshaft pulley. 6. Install crankshaft pulley puller tool No. J 24420-B or equivalent on hub. 7. Turn puller screw and remove hub. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Page 1379 INSTALLATION 1. Coat front cover seal contact area with engine oil. 2. Apply RTV sealer No. 1052917 or equivalent, to keyway in pulley hub. 3. Place crankshaft pulley hub into position over key on crankshaft. 4. Install crankshaft pulley installer No. J 29113 into crankshaft so that at least 1/4 inch of thread is engaged. 5. Pull pulley hub into position and remove tool from crankshaft. 6. Install crankshaft pulley, then three pulley retaining bolts. 7. Install inner slash shield, then wheel and tire assembly. 8. Lower vehicle and install serpentine belt. 9. Connect battery ground cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > VIN G & 4, Clearance Value Piston: Specifications Vin G, Clearance Value Vin G, Clearance Value Piston Clearance 0.0007-0.0017 in Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > VIN G & 4, Clearance Value > Page 1384 Piston: Specifications Piston Clearance .0007-.0017 in Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Oversize Availability Piston: Service and Repair Oversize Availability Pistons are available in standard size and oversize of 0.020 inch (0.5mm). Piston pins are available in standard size only. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Oversize Availability > Page 1387 Piston: Service and Repair Piston Measurements and Replacement Fig. 13 Installing Piston Assemble piston to rod, with arrow on piston facing toward front of engine Fig. 13. Upon installation measure connecting rod side clearance using a feeler gauge. Side clearance should be .0039 to .0149 inch. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Vin G, Piston Pin Dimensions Vin G, Piston Pin Dimensions Piston Pin Diameter 0.8000-0.8002 in Note: Pistons & pins are matched set and should be replaced as an assembly. Piston Pin To Piston Clearance 0.0004-0.0009 in Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 1391 Piston Pin: Service and Repair Pistons are available in standard size and oversize of 0.020 inch (0.5mm). Piston pins are available in standard size only. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Piston Ring Dimensions Piston Ring: Specifications Piston Ring End Gap Comp. 0.01 in Note: Minimum Oil 0.01 in Note: Minimum Piston Ring Side Clearance Comp. 0.0019 in Oil 0.0019 in Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Piston Ring Dimensions > Page 1396 Piston Ring: Specifications Vin G, Ring Dimensions Vin G, Ring Dimensions Piston Ring End Gap Compression 0.01 in Note: Minimum Oil 0.01 in Piston Ring Side Clearance Compression 0.0019 in Oil 0.0019 in Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1397 Piston Ring: Service and Repair Pistons are available in standard size and oversize of 0.020 inch (0.5mm). Piston pins are available in standard size only. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications ROCKER ARM TORQUE Fig. 7 Rocker Arm Cover, Rocker Arms & Pushrod Replacement ^ Rocker Arms are not adjustable on this engine, tighten Rocker Arm Nuts to 30 Nm (22 lbs. ft.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1402 Valve Clearance: Adjustments The Rocker Arms are not adjustable on this engine refer to Rocker Arm / Service and Repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1403 Valve Clearance: Service and Repair The Rocker Arms are not adjustable on this engine refer to Rocker Arm / Service and Repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair WARNING: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing fuel system components. After relieving system pressure, a small amount of fuel may be released when servicing fuel lines or connections. In order to reduce the chance of personal injury, cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when disconnect is completed. When servicing the fuel system use the following precautions: a. Put a "CAUTION FLAMMABLE" sign in the workshop. b. Be sure shop is supplied with an adequate fire extinguisher. c. Be sure to disconnect battery ground cable before any service work is done. d. Use a suitable container to catch any fuel that may leak from the system during service. e. Always relieve fuel system pressure before disconnecting any lines. f. If the key must be turned ON while servicing the fuel system, always disconnect or disable the ignition, to insure no sparks occur near fuel vapors. g. NEVER turn the ignition on while servicing the fuel system unless the electric fuel pump is disabled. PROCEDURE: 1. Loosen fuel filler cap to relieve tank vapor pressure. 2. Raise the vehicle and disconnect fuel pump electrical connector at fuel tank. 3. Lower vehicle. 4. START engine and RUN until fuel supply remaining in fuel pipes is consumed. Engage starter for 3 seconds to relieve the remaining fuel pressure. 5. Perform required tests or repairs. 6. Raise vehicle and reconnect fuel pump electrical connector at fuel tank. 7. START vehicle for 10 seconds. Shut vehicle OFF and check for leaks. 8. Retighten the fuel tank cap. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Rocker Arm Nut Torque Rocker Arm Assembly: Specifications Rocker Arm Nut Torque ROCKER ARM TORQUE Fig. 7 Rocker Arm Cover, Rocker Arms & Pushrod Replacement ^ Rocker Arms are not adjustable on this engine, tighten Rocker Arm Nuts to 30 Nm (22 lbs. ft.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Rocker Arm Nut Torque > Page 1411 Rocker Arm Assembly: Specifications Rocker Arm Stud Torque The OEM service manual does not provide a specification for this component. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1412 Rocker Arm Assembly: Adjustments ROCKER ARM ADJUSTMENT Fig. 7 Rocker Arm Cover, Rocker Arms & Pushrod Replacement ^ Rocker Arms are not adjustable on this engine, tighten Rocker Arm Nuts to 30 Nm (22 lbs. ft.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1413 Rocker Arm Assembly: Service and Repair ROCKER ARM AND push rod Fig. 7 Rocker Arm Cover, Rocker Arms & Pushrod Replacement (Figure 1) Roller Lifter And Anti-rotation Bracket Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1414 IMPORTANT ^ Place components in a rack in order of disassembly so they can be reinstalled at the same ocation and with the same mating surface as when removed. 1. Negative battery cable. 2. Valve rocker arm cover. 3. Rocker arm nut. 4. Rocker arm and ball. 5. Push rod. INSTALL OR CONNECT ^ Whenever new rocker arms and/or rocker arm balls are being installed, coat bearing surfaces of rocker arms and rocker arm balls with camshaft assembly lube GM P/N 1052365 or equivalent. 1. Push rods, making sure they seat in lifters. 2. Rocker arm and ball. 3. Apply Dri-Slide Molly lubricant GM P/N 1052948 or equivalent to threads of stud. 4. Rocker arm nuts. TIGHTEN ^ Nuts to 30 Nm (22 lbs. ft.). 5. Valve rocker arm cover. 6. Negative battery cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair Valve Cover: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect air hose at throttle body and air cleaner assembly, then disconnect PCV hose. 3. Remove rocker arm cover attaching bolts, then remove cover. 4. Reverse procedure to install, torque attaching bolts to specification. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Service and Repair Valve Guide: Service and Repair Valve guides are an integral part of the cylinder head and are not removable. If valve stem clearance becomes excessive, the valve guide should be reamed to the next oversize and the appropriate oversize valves installed. Valves are available in .00295, .0059 and .00984 inch oversizes. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Vin G, Seat Dimensions Vin G, Seat Dimensions Seat Angle 46 deg Seat Width Intake 0.0490-0.0590 in Exhaust 0.0630-0.0750 in Runout 0.002 in Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Vin G, Valve Spring Dimensions Vin G, Valve Spring Dimensions Free Length 2.06 in Installed Height 1.61 in Seated Pressuure 100-110 lbf at 1.61 in Compression Pressure 208-222 lbf at 1.22 in Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1427 Valve Spring: Service and Repair Fig. 9 Valves, Valve Seals & Valve Springs REMOVAL 1. Disconnect battery ground cable, then remove rocker cover. 2. With engine cold, remove spark plug and clean debris from plug recess. 3. Remove rocker arm and pushrod on cylinders to be serviced. 4. Install air line adapter tool No. J 23590 or equivalent in spark plug thread and apply compressed air to hold valves in place. 5. With valve spring compressor tool No. J 5892-B on 1990 models, tool No. J 5892-C on 1991--92 models or equivalents, compress valve spring and remove valve lock and cap, Fig. 9. 6. Remove spring, valve stem oil seal and shim. INSTALLATION 1. Install shim if required, then new valve stem oil seal. 2. Set valve spring and cap in place. 3. Using valve spring compressor tool No. J 5892-B on 1990 models, tool No. J 5892-C on 1991-92 models or equivalents, compress valve spring. 4. Install valve locks and release compressor. Make sure locks seat properly in the upper groove of the valve stem. Grease may be used to hold the locks in place while releasing the compressor tool. 5. Install spark plug, pushrods, rocker arms and rocker cover. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Valve Specifications Valve: Specifications Vin G, Valve Dimensions Vin G, Valve Dimensions Face Angle 45 deg Margin 0.031 in Note: Minimum Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Valve Specifications > Page 1432 Valve: Specifications Vin G, Valve Guide Clearance Vin G, Valve Guide Clearance Stem To Guide Clearance Intake 0.0011-0.0026 in Exhaust 0.0014-0.0030 in Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 1438 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 1439 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1440 Drive Belt: Service and Repair Serpentine Belt Routing 1. Remove coolant reservoir. 2. Rotate tensioner clockwise with a 15 mm wrench and slide belt from generator pulley. Release tensioner and remove belt. 3. Reverse procedure to install, routing belt as shown in Fig. 22. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair Drive Belt Tensioner: Service and Repair 1. Disconnect negative battery cable and remove coolant reservoir. 2. Remove serpentine belt as described under SERPENTINE DRIVE BELT. 3. Remove two generator bolts. 4. Remove power steering pump and position aside. 5. Remove tensioner bolts and tensioner. 6. Reverse procedure to install, Torquing tensioner bolts to 37 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair Engine Mount: Service and Repair Fig. 1 Front Engine Mount FRONT ENGINE MOUNT 1. Disconnect battery ground cable. 2. Remove upper engine mount to body bolts, Fig. 1. 3. Remove upper engine mount to engine bracket bolt. 4. Raise and support vehicle. 5. Using a suitable jack, support engine assembly. 6. Remove inner fender shield. 7. Remove lower engine mount to body bolt. 8. Remove lower engine mount to engine mount bracket bolt, then remove mount. 9. Reverse procedure to install, torque bolts and nuts to specifications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Page 1447 Fig. 2 Rear Engine Mount REAR ENGINE MOUNT 1. Disconnect battery ground cable. 2. Raise and support vehicle. 3. Remove engine mount retaining bolts and nuts, Fig. 2, then remove mount. 4. Reverse procedure to install, torque bolts and nuts to specifications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Vin G, Overhead Valve Engine, Oil Pressure Vin G, Overhead Valve Engine, Oil Pressure Normal Oil Pressure 63-77 psi Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 1456 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 1457 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil without Filter ....................................................................................................................... ............................................... 4.0 quarts (3.8 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Page 1464 Oil Filter: Technical Service Bulletins Oil Filter - Replacement Information Number: 91-227-6A Section: 6A Date: March 1991 Corporate Bulletin No.: 136105 Subject: CORRECT OIL FILTER Model and Year: 1991 CAVALIER WITH 2.2L ENGINE This bulletin advises dealers and customers of the correct replacement oil filter for the 1991 Cavalier. Disregard information contained in the 1991 Cavalier Owners Manual showing the AC TYPE PF-40 as the replacement oil filter. The proper replacement oil filter for the 1991 Cavalier is the AC TYPE PF-52. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair Oil Pan: Service and Repair 1. Disconnect battery ground cable. 2. Raise and support vehicle, then disconnect exhaust pipe from the exhaust manifold. 3. Drain engine oil, then remove starter bracket at block. 4. Remove starter and position aside, then remove flywheel cover. 5. Remove four right side engine support bolts, then lower support slightly to gain clearance for oil pan removal. 6. On models with automatic transaxle, remove oil filter and extension. 7. On all models, remove oil pan retaining bolts and oil pan. 8. Reverse procedure to install, noting the following: a. Apply a 1/16 inch diameter bead of GM 1052914 RTV or equivalent, on oil pan to block sealing flanges. b. Apply RTV sealer or equivalent to oil pan surface which fits to engine front cover. c. Using a new oil pan rear seal, apply a thin coat of RTV sealer or equivalent on ends down to ears, install pan against cylinder case and install bolts. d. On models with automatic transaxle, replace oil filter adapter seal and install oil filter adapter. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High Oil Pressure Gauge: Customer Interest Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High > Page 1476 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High Oil Pressure Gauge: All Technical Service Bulletins Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High > Page 1482 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Page 1483 Oil Pressure Gauge: Description and Operation This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuated the contact on the variable resistor, in turn controlling current flow through the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge reading. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Page 1484 Oil Pressure Gauge: Testing and Inspection Disconnect the oil pressure gauge lead from the sending unit, connect a 12 volt test lamp between the gauge lead and the ground and turn ignition on. If test lamp flashes, the instrument voltage regulator is functioning properly and the gauge circuit is not broken. If the test lamp remains lit, the instrument voltage regulator is defective and must be replaced. If the test lamp does not light, check the instrument voltage regulator for proper ground or an open circuit. Also, check for an open in the instrument voltage regulator to oil pressure gauge wire or in the gauge itself. If test lamp flashes and gauge is not accurate, the gauge may be out of calibration, requiring replacement. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High Oil Pressure Sender: Customer Interest Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High > Page 1493 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High Oil Pressure Sender: All Technical Service Bulletins Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High > Page 1499 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > Page 1500 Oil Pressure Sender: Locations Rear Of Engine RH rear of engine, below intake manifold Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations Rear Of Engine RH rear of engine, below intake manifold Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1504 Oil Pressure Switch (For Fuel Pump): Description and Operation Wiring Diagram For Fuel Pump Relay As a back-up system to the fuel pump relay, the fuel pump can also be turned ON by the oil pressure switch. The oil pressure switch is a normally open switch which closes when oil pressure reaches about 28.0 kPa (4.0 psi). If the fuel pump relay fails, the oil pressure switch will power the fuel pump. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1505 Oil Pressure Switch (For Fuel Pump): Testing and Inspection Wiring Diagram For Fuel Pump Relay The oil pressure switch is mounted on the engine. This switch operates as a parallel power supply with the fuel pump relay to supply battery voltage to the fuel pump. Voltage is supplied to the fuel pump after approximately 28 kPa (4 PSI) oil pressure is reached. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1506 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch Located On RH Side Of Engine. Oil sender is located on right hand side of engine, under the DIS coils, under the intake manifold. Remove oil sender by using correct tool on the base of the sending unit. Do not use the body of the oil sender for installation/removal. Use appropriate sealer on threads. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation Many cars utilize a warning light on the instrument panel in place of the conventional dash indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is wired in series with the ignition switch and the engine unit, which is an oil pressure switch. The oil pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on, the warning light circuit is energized and the circuit is completed through the closed contacts in the pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm, opening the contacts, thereby breaking the circuit and putting out the light. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 1510 Oil Pressure Warning Lamp/Indicator: Testing and Inspection On some models, the oil pressure indicator light also serves as the electric choke defect indicator. If Oil or engine indicator light does not light, check to ensure electric choke is not disconnected at carburetor. Also check for defect in electric choke heater, blown gauge fuse or defect in lamp or wiring circuit. If indicator light stays on with engine running possible causes are: oil pressure is low, switch to indicator light wiring has an open circuit, oil pressure switch wire connector has disconnected or on some models, gauge or radio fuse has blown. The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. The presence of sealing compound on the threads of the engine unit will cause a poor ground. If the warning light remains lit when it normally should be out, replace the engine unit before proceeding to determine the cause for a low pressure indication. The warning light sometimes will light up or will flicker when the engine is idling, even though the oil pressure is adequate. However, the light should go out when the engine speed is increased. There is no cause for alarm in such cases; it simply means that the pressure switch is not calibrated precisely correct. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Vin G, Overhead Valve Engine, Oil Pressure Vin G, Overhead Valve Engine, Oil Pressure Normal Oil Pressure 63-77 psi Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement Intake Manifold: 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1519 Intake Manifold: Specifications Fig. 5 Engine Fuel Hoses & Pipes Fig. 7 Intake Manifold Bolt Tightening Sequence. 1990-91 1. Disconnect battery ground cable, then remove fuel filler cap to relieve fuel tank pressure. 2. Remove air cleaner assembly, then drain engine coolant. 3. Disconnect vacuum lines and wires from the intake as necessary. 4. Disconnect fuel feed and return lines, Fig. 5. 5. Disconnect TBI linkage and TBI assembly, then remove the power steering pump and position aside. 6. Disconnect coolant hose to intake manifold. 7. Raise and support vehicle. 8. On 1990 models, remove coolant pipe retaining nut, located on top of the D.I.S, and move the pipe rearward. 9. On all models, disconnect accelerator and T.V. cables, then remove the bracket. 10. Remove lower intake manifold retaining nuts, then lower the vehicle. 11. Remove upper intake manifold retaining bolts and nuts, then remove intake manifold. 12. Reverse procedure to install, torque bolts to specifications in sequence shown in Fig. 7. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1520 Intake Manifold: Service and Repair Fig. 5 Engine Fuel Hoses & Pipes Fig. 7 Intake Manifold Bolt Tightening Sequence. 1990-91 1. Disconnect battery ground cable, then remove fuel filler cap to relieve fuel tank pressure. 2. Remove air cleaner assembly, then drain engine coolant. 3. Disconnect vacuum lines and wires from the intake as necessary. 4. Disconnect fuel feed and return lines, Fig. 5. 5. Disconnect TBI linkage and TBI assembly, then remove the power steering pump and position aside. 6. Disconnect coolant hose to intake manifold. 7. Raise and support vehicle. 8. On 1990 models, remove coolant pipe retaining nut, located on top of the D.I.S, and move the pipe rearward. 9. On all models, disconnect accelerator and T.V. cables, then remove the bracket. 10. Remove lower intake manifold retaining nuts, then lower the vehicle. 11. Remove upper intake manifold retaining bolts and nuts, then remove intake manifold. 12. Reverse procedure to install, torque bolts to specifications in sequence shown in Fig. 7. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High Oil Pressure Gauge: Customer Interest Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High > Page 1530 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High Oil Pressure Gauge: All Technical Service Bulletins Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High > Page 1536 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Page 1537 Oil Pressure Gauge: Description and Operation This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuated the contact on the variable resistor, in turn controlling current flow through the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge reading. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Page 1538 Oil Pressure Gauge: Testing and Inspection Disconnect the oil pressure gauge lead from the sending unit, connect a 12 volt test lamp between the gauge lead and the ground and turn ignition on. If test lamp flashes, the instrument voltage regulator is functioning properly and the gauge circuit is not broken. If the test lamp remains lit, the instrument voltage regulator is defective and must be replaced. If the test lamp does not light, check the instrument voltage regulator for proper ground or an open circuit. Also, check for an open in the instrument voltage regulator to oil pressure gauge wire or in the gauge itself. If test lamp flashes and gauge is not accurate, the gauge may be out of calibration, requiring replacement. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation Many cars utilize a warning light on the instrument panel in place of the conventional dash indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is wired in series with the ignition switch and the engine unit, which is an oil pressure switch. The oil pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on, the warning light circuit is energized and the circuit is completed through the closed contacts in the pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm, opening the contacts, thereby breaking the circuit and putting out the light. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 1542 Oil Pressure Warning Lamp/Indicator: Testing and Inspection On some models, the oil pressure indicator light also serves as the electric choke defect indicator. If Oil or engine indicator light does not light, check to ensure electric choke is not disconnected at carburetor. Also check for defect in electric choke heater, blown gauge fuse or defect in lamp or wiring circuit. If indicator light stays on with engine running possible causes are: oil pressure is low, switch to indicator light wiring has an open circuit, oil pressure switch wire connector has disconnected or on some models, gauge or radio fuse has blown. The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. The presence of sealing compound on the threads of the engine unit will cause a poor ground. If the warning light remains lit when it normally should be out, replace the engine unit before proceeding to determine the cause for a low pressure indication. The warning light sometimes will light up or will flicker when the engine is idling, even though the oil pressure is adequate. However, the light should go out when the engine speed is increased. There is no cause for alarm in such cases; it simply means that the pressure switch is not calibrated precisely correct. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 Fig. 14 Crankshaft Rear Seal Removal 1. Remove transaxle from vehicle as described in TRANSMISSIONS CLUTCHES DIFFERENTIALS AXLES AND DRIVE SHAFTS/MANUAL TRANSAXLE/COMPONENT REPLACEMENT AND REPAIR PROCEDURES/MANUAL TRANSAXLE. 2. On models with manual transaxle, remove pressure plate and clutch disc. 3. On all models, remove flywheel attaching bolts and flywheel. 4. Insert a screwdriver or similar tool in through the dust lip as shown in Fig. 14, pry out seal. 5. Reverse procedure to install, noting the following: a. Lubricate seal bore to seal surface with engine oil. b. Using seal installation tool No. J 34686 or equivalent, align dowel pin of tool with dowel pin hole in crankshaft and attach tool to crankshaft. c. Torque tool attaching screws to 27-62 inch lbs., then tighten tool T handle to push seal into bore. Continue to tighten until tool is flush against block. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 Fig. 9 Valves, Valve Seals & Valve Springs REMOVAL 1. Disconnect battery ground cable, then remove rocker cover. 2. With engine cold, remove spark plug and clean debris from plug recess. 3. Remove rocker arm and pushrod on cylinders to be serviced. 4. Install air line adapter tool No. J 23590 or equivalent in spark plug thread and apply compressed air to hold valves in place. 5. With valve spring compressor tool No. J 5892-B on 1990 models, tool No. J 5892-C on 1991--92 models or equivalents, compress valve spring and remove valve lock and cap, Fig. 9. 6. Remove spring, valve stem oil seal and shim. INSTALLATION 1. Install shim if required, then new valve stem oil seal. 2. Set valve spring and cap in place. 3. Using valve spring compressor tool No. J 5892-B on 1990 models, tool No. J 5892-C on 1991-92 models or equivalents, compress valve spring. 4. Install valve locks and release compressor. Make sure locks seat properly in the upper groove of the valve stem. Grease may be used to hold the locks in place while releasing the compressor tool. 5. Install spark plug, pushrods, rocker arms and rocker cover. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High Oil Pressure Sender: Customer Interest Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High > Page 1559 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High Oil Pressure Sender: All Technical Service Bulletins Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High > Page 1565 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Page 1566 Oil Pressure Sender: Locations Rear Of Engine RH rear of engine, below intake manifold Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations Rear Of Engine RH rear of engine, below intake manifold Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1570 Oil Pressure Switch (For Fuel Pump): Description and Operation Wiring Diagram For Fuel Pump Relay As a back-up system to the fuel pump relay, the fuel pump can also be turned ON by the oil pressure switch. The oil pressure switch is a normally open switch which closes when oil pressure reaches about 28.0 kPa (4.0 psi). If the fuel pump relay fails, the oil pressure switch will power the fuel pump. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1571 Oil Pressure Switch (For Fuel Pump): Testing and Inspection Wiring Diagram For Fuel Pump Relay The oil pressure switch is mounted on the engine. This switch operates as a parallel power supply with the fuel pump relay to supply battery voltage to the fuel pump. Voltage is supplied to the fuel pump after approximately 28 kPa (4 PSI) oil pressure is reached. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1572 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch Located On RH Side Of Engine. Oil sender is located on right hand side of engine, under the DIS coils, under the intake manifold. Remove oil sender by using correct tool on the base of the sending unit. Do not use the body of the oil sender for installation/removal. Use appropriate sealer on threads. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair Camshaft Gear/Sprocket: Service and Repair Fig.11 Timing Chain & Sprockets Timing Chain Tensioner 1. Disconnect battery ground cable, then remove crankcase front cover as described in CRANKCASE FRONT COVER. 2. Align marks on crankshaft sprocket and camshaft sprocket, Fig. 11. 3. Remove timing chain tensioner upper bolt, then loosen timing chain tensioner Torx as far as possible, but do not remove. 4. Remove camshaft sprocket and timing chain. 5. Using puller tool No. J 22888 on 1990 models, tool No. J 22888-20 on 1991 models or equivalents, remove crankshaft sprocket. 6. Reverse procedure to install, noting the following: a. Compress tensioner spring, then install a cotter pin or nail into hole A as shown in Fig. 12. b. Lube timing chain and sprockets with engine oil, lube thrust thrust surface with camshaft assembly lube No. 1052365 or equivalent. c. Align marks on camshaft and crankshaft sprockets with tabs on tensioner as shown in Fig. 12. d. Align dowel in camshaft with dowel hole camshaft sprocket. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Page 1577 e. Draw camshaft sprocket onto camshaft using the mounting bolt. Torque to specifications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair Crankshaft Gear/Sprocket: Service and Repair Fig.11 Timing Chain & Sprockets Timing Chain Tensioner 1. Disconnect battery ground cable, then remove crankcase front cover as described in CRANKCASE FRONT COVER. 2. Align marks on crankshaft sprocket and camshaft sprocket, Fig. 11. 3. Remove timing chain tensioner upper bolt, then loosen timing chain tensioner Torx as far as possible, but do not remove. 4. Remove camshaft sprocket and timing chain. 5. Using puller tool No. J 22888 on 1990 models, tool No. J 22888-20 on 1991 models or equivalents, remove crankshaft sprocket. 6. Reverse procedure to install, noting the following: a. Compress tensioner spring, then install a cotter pin or nail into hole A as shown in Fig. 12. b. Lube timing chain and sprockets with engine oil, lube thrust thrust surface with camshaft assembly lube No. 1052365 or equivalent. c. Align marks on camshaft and crankshaft sprockets with tabs on tensioner as shown in Fig. 12. d. Align dowel in camshaft with dowel hole camshaft sprocket. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Page 1581 e. Draw camshaft sprocket onto camshaft using the mounting bolt. Torque to specifications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Fig.11 Timing Chain & Sprockets Timing Chain Tensioner 1. Disconnect battery ground cable, then remove crankcase front cover as described in CRANKCASE FRONT COVER. 2. Align marks on crankshaft sprocket and camshaft sprocket, Fig. 11. 3. Remove timing chain tensioner upper bolt, then loosen timing chain tensioner Torx as far as possible, but do not remove. 4. Remove camshaft sprocket and timing chain. 5. Using puller tool No. J 22888 on 1990 models, tool No. J 22888-20 on 1991 models or equivalents, remove crankshaft sprocket. 6. Reverse procedure to install, noting the following: a. Compress tensioner spring, then install a cotter pin or nail into hole A as shown in Fig. 12. b. Lube timing chain and sprockets with engine oil, lube thrust thrust surface with camshaft assembly lube No. 1052365 or equivalent. c. Align marks on camshaft and crankshaft sprockets with tabs on tensioner as shown in Fig. 12. d. Align dowel in camshaft with dowel hole camshaft sprocket. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 1585 e. Draw camshaft sprocket onto camshaft using the mounting bolt. Torque to specifications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Technical Service Bulletins > Camshaft Rear Cover Bolt - Torque Specification Revised Timing Cover: Technical Service Bulletins Camshaft Rear Cover Bolt - Torque Specification Revised File In Section: 6 - Engine Bulletin No.: 67-61-13 Date: April, 1996 SERVICE MANUAL UPDATE Subject: Section 6A2 - Engine Mechanical - Camshaft Rear Cover Bolt Torque Specification Models: 1993-96 Buick Century 1990-96 Chevrolet Beretta, Cavalier, Corsica 1993-96 Oldsmobile Cutlass Ciera 1990-93 Pontiac Tempest (GM of Canada only) 1995-96 Pontiac Sunfire 1994-96 Chevrolet and GMC S Models with 2.2L Engine (VINs G, 4 - RPOs LM3, LN2) The camshaft rear cover bolt torque was omitted from some of the service manuals. Camshaft Rear Cover Bolt Torque Specification: The torque specification for the camshaft rear cover is 12 N.m (106 lb.in.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Technical Service Bulletins > Page 1590 Timing Cover: Service and Repair 1. Disconnect battery ground cable. 2. Remove serpentine belt, then the belt tensioner. 3. Raise and support vehicle, then remove oil pan as described in OIL PAN. 4. Remove crankshaft pulley and hub as described in CRANKSHAFT PULLEY AND HUB. 5. Remove front cover retaining bolts, then remove front cover. 6. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure, Engine Running ......................................................................................................................................................... 62-90 kPa (9-13 P.S.I.) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1595 Fuel Pressure: Testing and Inspection Fuel System Schematic WARNING: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before connecting a fuel pressure test. Refer to Fuel Pressure Release Procedure. CAUTION To reduce the risk of fire and personal injury: 1. It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge. 2. A small amount of fuel may be released when disconnecting the fuel lines. Cover the fuel lines with a shop towel to catch any fuel leaking out. Place the towel in an approved container once the lines are disconnected. 3. DO NOT pinch or restrict nylon fuel lines to avoid severing. If nylon fuel lines become kinked, and cannot be straightened, they must be replaced. 4. Wear safety glasses at all times. FUEL PRESSURE TESTING 1. Loosen fuel filler cap to relieve fuel tank pressure. (DO NOT tighten at this time.) 2. Raise the vehicle to disconnect the fuel pump electrical connector, then lower the vehicle. 3. Start and run the engine until the residual fuel is consumed. Engage starter for three seconds to assure fuel pressure relief. 4. Disconnect the negative battery cable, and locate the fuel feed pressure line. 5. Connect fuel pressure gage, J-29658-B, in between the fuel feed line and the TBI unit. Use the appropriate adapters. 6. Raise the vehicle to connect the fuel pump electrical connector, then lower the vehicle. 7. Connect the negative battery terminal. 8. Perform fuel pressure checks. 9. Relieve the fuel system pressure. See steps 2 and 3. 10. Disconnect the negative battery terminal and remove fuel pressure gauge. 11. Tighten fuel filler cap and connect the negative battery terminal. 12. Cycle the ignition switch twice, waiting ten seconds between cycles. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Vin R, U, G, Minimum Idle Speed Vin R, U, G, Minimum Idle Speed Idle Speed Note: Let engine idle until proper fuel control status is closed loop. Manual Transmission Neutral 600 +/-50 rpm Automatic Transmission Drive 600 +/-50 rpm Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Idle Speed Idle Speed: Adjustments Idle Speed The throttle plate stop screw, or idle speed, is adjusted at the factory and covered with a plug to discourage unnecessary adjustment. But, if access to the throttle stop screw is necessary, the following procedure eliminates the removal of the Throttle Body unit from the intake manifold. If there is a complaint of high idle speed, vacuum leaks should be considered the most likely cause. The Electronic Control Module (ECM) controls the Idle Air Control (IAC) valve, and it is less likely that a stalling complaint would be due to incorrect idle speed. If either occurs see DIAGNOSIS BY SYMPTOM. If the Minimum Air Rate is suspected, be sure the Idle Air Control (IAC) valve is not "lost" (not actually at the location indicated by current IAC "counts"). The IAC valve could be "lost" if ECM power has been interrupted with the ignition "ON," or the IAC valve has been disconnected with the engine running since the last reset. CAUTION: To prevent engines from running at high speeds, be sure that the ignition is OFF and the vehicle is in PARK or NEUTRAL before connecting Idle Air Control (IAC) assembly, or installing/removing idle air passage plugs. Failure to do this may result in vehicle movement, which can result in personal and/or property damage. Stop Screw Plug Removal The Idle Speed may be checked using the following procedure: 1. Block drive wheels and apply parking brake. 2. Remove the air cleaner housing, and plug the Thermac vacuum port (if applicable). 3. Remove the idle stop screw plug with an awl. 4. Start the engine and allow it to reach operating temperature. 5. Connect a tachometer to the engine. 6. With Idle Air Control (IAC) valve connected, jump terminals A and B of the ALDL connector to ground the diagnostic terminal. See ON-BOARD DIAGNOSTIC CHECK for ALDL diagram. 7. Turn the ignition ON, but do not start the engine. Wait at least 45 seconds to allow the IAC pintle time to bottom in its seat. This closes the air passage in the TBI unit. 8. With the ignition ON, engine not running and diagnostic lead grounded, disconnect the IAC valve electrical connector. 9. Remove the ground from the diagnostic connector, and start the engine. Allow the engine speed to stabilize. 10. Adjust the idle stop screw. See MECHANICAL SPECIFICATIONS for idle speed specifications. 11. Turn OFF the ignition and reconnect the IAC electrical connector. 12. Reset the IAC valve by starting the engine and allowing it to run at 2000 rpm for ten seconds. Then turn OFF the ignition switch. 13. Cover the idle stop screw with silicone or similar sealant. 14. Remove the test instruments and reinstall the air cleaner housing. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Idle Speed > Page 1601 Idle Speed: Adjustments Minimum Air Rate - Fuel Injection Only NOTE: The minimum idle air rate is set at the factory with a stop screw and is not normally readjusted unless repairs or replacement of the throttle body assembly has occurred. Engine idle speed is computer controlled through the IAC valve and is not adjustable. If there is a complaint of high idle speed, vacuum leaks should be considered the most likely cause. The Electronic Control Module (ECM) controls the Idle Air Control (IAC) valve, and it is less likely that a stalling complaint would be due to incorrect minimum idle speed. If either occurs, refer to Diagnosis by Symptom. If the Minimum Air Rate is suspected, be sure the Idle Air Control (IAC) valve is not "lost" (not actually at the location indicated by current IAC "counts"). The IAC valve could be "lost" if ECM power has been interrupted with the ignition "ON," or the IAC valve has been disconnected with the engine running since the last reset. CAUTION: To prevent engines from running at high speeds, be sure that the ignition is OFF and the vehicle is in PARK or NEUTRAL before connecting Idle Air Control (IAC) assembly, or installing/removing idle air passage plugs. Failure to do this may result in vehicle movement, which can result in personal and/or property damage. MINIMUM IDLE AIR RATE CHECK 1. START engine and bring it to normal operating temperatures 185-212 degrees Fahrenheit (85-100 degrees Celsius). Turn engine OFF. 2. Remove air cleaner assembly. Remove hoses and plug any possible air sources on tube manifold assembly. 3. Disconnect throttle cable. 4. Ground diagnostic "test" terminal in ALDL connector. (jumper A to B) 5. Turn ON ignition, DO NOT START engine. Wait at least 10 seconds (this will allow the IAC pintle to extend and seat in the throttle body). 6. With ignition ON, engine stopped, test terminal still grounded, disconnect IAC valve electrical connector. (This disables the IAC valve in the seated position). Remove the ground from the diagnostic terminal. 7. Connect a scan tool to the ALDL connector and place in open mode. If a tool is not available connect a tachometer to the engine. 8. START engine. With transmission in NEUTRAL, allow engine rpm to stabilize. It may be necessary to depress the accelerator in order to start the engine. 9. Idle speed should be 550 to 650 RPM. Adjust idle stop screw if necessary. To remove the soft plug, puncture with an awl and pry out. Stop Screw Plug Removal 10. If the minimum idle air rate is within 550 to 650 RPM, no further check is required. 11. Turn ignition OFF and reconnect IAC valve electrical connector. 12. Disconnect the SCAN tool or tachometer. 13. The IAC valve will be reset by the computer when the vehicle speed exceeds 43 MPH while the engine speed is above 2000 RPM or when the diagnostic test connector is grounded when the engine RPM is above 2000 RPM. 14. Install air cleaner, adapter, gasket and vacuum hoses. NOTE: The minimum idle air rate is set at the factory with a stop screw, which is covered with a tamper plug. This setting allows enough air flow by the Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Idle Speed > Page 1602 throttle valves to cause the IAC valve pintle to be positioned a calibrated number of steps (counts), from the seat, during "controlled" idle operation. If the IAC valve is disconnected and reconnected with the engine running, the idle speed may be wrong. In this case, the IAC valve can be reset by doing the following: The IAC valve will be reset by the computer when the vehicle speed exceeds 43 MPH while the engine speed is above 2000 RPM or when the diagnostic test connector is grounded when the engine RPM is above 2000 RPM. Engine idle speed is computer controlled through the IAC valve, by driving the IAC pintle in and out. Engine idle speed is a funtion of total air flow into the engine based on: IAC valve position, throttle valve opening (idle stop screw), calibrated leakage through the accessories, PCV flow. "Controlled" idle speed is programed into the ECM, which determines the correct IAC valve pintle position to maintain the desired idle speed. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 1612 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 1618 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 Release: Service and Repair WARNING: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing fuel system components. After relieving system pressure, a small amount of fuel may be released when servicing fuel lines or connections. In order to reduce the chance of personal injury, cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when disconnect is completed. When servicing the fuel system use the following precautions: a. Put a "CAUTION FLAMMABLE" sign in the workshop. b. Be sure shop is supplied with an adequate fire extinguisher. c. Be sure to disconnect battery ground cable before any service work is done. d. Use a suitable container to catch any fuel that may leak from the system during service. e. Always relieve fuel system pressure before disconnecting any lines. f. If the key must be turned ON while servicing the fuel system, always disconnect or disable the ignition, to insure no sparks occur near fuel vapors. g. NEVER turn the ignition on while servicing the fuel system unless the electric fuel pump is disabled. PROCEDURE: 1. Loosen fuel filler cap to relieve tank vapor pressure. 2. Raise the vehicle and disconnect fuel pump electrical connector at fuel tank. 3. Lower vehicle. 4. START engine and RUN until fuel supply remaining in fuel pipes is consumed. Engage starter for 3 seconds to relieve the remaining fuel pressure. 5. Perform required tests or repairs. 6. Raise vehicle and reconnect fuel pump electrical connector at fuel tank. 7. START vehicle for 10 seconds. Shut vehicle OFF and check for leaks. 8. Retighten the fuel tank cap. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Ignition Firing Order Firing Order: Specifications Ignition Firing Order Firing Order ......................................................................................................................................... ....................................................................... 1-3-4-2 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations > Number 1 Cylinder Location Number One Cylinder: Locations Number 1 Cylinder Location NUMBER ONE CYLINDER LOCATION Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug Wire: > 93356D > Oct > 92 > Engine - Miss, Hesitation, or Roughness Spark Plug Wire: Customer Interest Engine - Miss, Hesitation, or Roughness Number: 93-35-6D Section: 6D Date: OCT. 1992 Corporate Bulletin No.: 716404R ASE No.: A1, A8 Subject: ENGINE MISS HESITATION OR ROUGHNESS DUE TO PIERCED SECONDARY IGNITION COMPONENTS Model and Year: 1980-93 ALL PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 87-121, DATED MAY 1987. THE 1989-93 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 87-121 SHOULD BE DISCARDED. During the diagnosis procedure for an engine miss, hesitation or roughness, a spark plug or spark plug wire condition may be suspected. Several types of commercial or homemade diagnostic equipment required the secondary ignition boots or wire to be pierced. This is normally done to check for spark plug firing or to perform a cylinder balance test. Similarly the use of pliers or other such tools to disengage a spark plug boot may pierce or damage the boot or wire. Secondary ignition components should not be pierced for any reason. Piercing a spark plug wire and/or distributor boot may create a condition that will not be immediately apparent. Over time, the hole in the pierced boot may allow a ground path to develop creating a plug misfire condition. Heavily moisture laden air in the vicinity of the pierced boot may accelerate this effect. Piercing a secondary ignition wire creates a gap in the wire's conductive core. This gap is a point of high resistance. The current flow in the wire will increase to compensate for the higher wire resistance. Over time, the wire may fail creating a plug misfire condition. The time required for the condition to appear depends upon the extent of damage to the conductive core. To help prevent future condition that are spark plug wire related, do not pierce or otherwise damage any secondary ignition component. Only use diagnostic equipment containing an inductive pick-up to check for spark plug firing or to perform cylinder balance tests. When disengaging a spark plug boot from the spark plug, twist the flanged boot 1/2 turn then pull on the boot only to remove the wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug Wire: > 93356D > Oct > 92 > Engine - Miss, Hesitation, or Roughness Spark Plug Wire: All Technical Service Bulletins Engine - Miss, Hesitation, or Roughness Number: 93-35-6D Section: 6D Date: OCT. 1992 Corporate Bulletin No.: 716404R ASE No.: A1, A8 Subject: ENGINE MISS HESITATION OR ROUGHNESS DUE TO PIERCED SECONDARY IGNITION COMPONENTS Model and Year: 1980-93 ALL PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 87-121, DATED MAY 1987. THE 1989-93 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 87-121 SHOULD BE DISCARDED. During the diagnosis procedure for an engine miss, hesitation or roughness, a spark plug or spark plug wire condition may be suspected. Several types of commercial or homemade diagnostic equipment required the secondary ignition boots or wire to be pierced. This is normally done to check for spark plug firing or to perform a cylinder balance test. Similarly the use of pliers or other such tools to disengage a spark plug boot may pierce or damage the boot or wire. Secondary ignition components should not be pierced for any reason. Piercing a spark plug wire and/or distributor boot may create a condition that will not be immediately apparent. Over time, the hole in the pierced boot may allow a ground path to develop creating a plug misfire condition. Heavily moisture laden air in the vicinity of the pierced boot may accelerate this effect. Piercing a secondary ignition wire creates a gap in the wire's conductive core. This gap is a point of high resistance. The current flow in the wire will increase to compensate for the higher wire resistance. Over time, the wire may fail creating a plug misfire condition. The time required for the condition to appear depends upon the extent of damage to the conductive core. To help prevent future condition that are spark plug wire related, do not pierce or otherwise damage any secondary ignition component. Only use diagnostic equipment containing an inductive pick-up to check for spark plug firing or to perform cylinder balance tests. When disengaging a spark plug boot from the spark plug, twist the flanged boot 1/2 turn then pull on the boot only to remove the wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Technical Service Bulletins > Page 1645 Spark Plug Wire: Specifications Ignition Wire Resistance: 1-15 in. ................................................................................................................................................. .......................................... 3000/10,000 ohms 15-25 in. ..................................................................... .................................................................................................................... 4000/15,000 ohms 25-35 in. ......................................................................................................................................................... ................................ 6000/20,000 ohms OVER 35 in. ......................................................................... .......................................................................................................... 8000/25,000 ohms Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Locations > Spark Plug Wire Routing Ignition Wire Location Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Locations > Spark Plug Wire Routing > Page 1648 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plug - Torque Specification Update Spark Plug: Technical Service Bulletins Spark Plug - Torque Specification Update Number: 91-79-6A Section: 6A Date: October 1990 Corporate Bulletin No.: Subject: SPARK PLUG TORQUE SPECIFICATIONS Model and Year: 1990 CELEBRITY 1990-91 BERETTA, CORSICA CAMARO, CAVALIER AND LUMINA, 1990-91 U VAN (APV) TO: ALL CHEVROLET DEALERS When installing spark plugs in the 3.1L engine use the following revised specification in the Service Manuals listed below: Cast Iron or Aluminum Heads, 15 N-m (11 lbs.ft.) 1991 Lumina Pages 6D4 - 4, 5, 7 Cavalier Pages 6A3 - 19 Camaro Pages 6A2 - 31 Pages 6D4 - 7, 9 Corsica/Beretta Pages 6D4 - 3, 6 Pages 6A5 - 24 Lumina (APV) Pages 6A4 - 20, 46 and 6D4 - 6 1990 Celebrity Pages 6D4 - 3, 5 Lumina Pages 6D4 - 4, 5, 6 Cavalier Pages 6A3 - 19 Pages 6D4 - 3 Camaro Pages 6A2 - 30 Pages 6D4 - 7, 8 Corsica/Beretta Pages 6A5 - 20 Pages 6D4 - 2 Lumina (APV) Pages 6A4 - 17, 41 and 6D4 - 6 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plug - Torque Specification Update > Page 1653 Spark Plug: Technical Service Bulletins Spark Plugs - Revised Number: 93-03-6D Section: 6D Date: AUGUST 1992 Corporate Bulletin No.: 166001R ASE No.: Al, A6, A8 Subject: NEW DESIGN SPARK PLUGS Model and Yew: 1991-93 ALL PASSENGER CARS AND TRUCKS WITH GASOLINE ENGINES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO., 91-234A-OB, DATED JULY 1992. THE 1992 AND 1993 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 91-234A-OB SHOULD BE DISCARDED. In 1991 GM introduced a new design spark plug for use in all trucks equipped with gas engines. These new design spark plugs have a ceramic insulator which is approximately 1/8 inch longer than the insulator used in previous model years. The longer length spark plugs, which conform to S.A.E. and I.S.O. Engineering guidelines, magnify the problem of cracked insulators because currently, most spark plug sockets are not of sufficient length to properly engage the shell hex. If the spark plug shell hex is not fully engaged in the spark plug socket wrench, the socket may cock at an angle and cause insulator cracking and/or breakage during plug installation or removal. When servicing these new design spark plugs, make sure that the spark plug socket being used is deep enough to accommodate the longer length insulator. The spark plug socket wrench should conform to the proposed S.A.E. and I.S.O. world standards for spark plug socket wrenches. Spark plug socket wrenches that conform to these standards are designed to accept the lengthened spark plugs and allow full engagement of the hex nut on the shell of the spark plug. Use of a spark plug socket which is NOT deep enough may result in the ceramic insulator becoming cracked above the spark plug shell. Note: SOME CRACKS IN THE INSULATOR M" NOT BE VISIBLE. SUCH CRACKS MAY LATER CAUSE A SPARK PLUG TO MISFIRE. SPARK PLUG MISFIRES ARE OFTEN MISDIAGNOSED AS A SLIPPING TRANSMISSION, DEFECTIVE TORQUE CONVERTER CLUTCH, ENGINE IMBALANCE, OR MALFUNCTIONING FUEL SYSTEM. To prevent insulator damage, it is recommended that the proper spark plug socket wrench be used when removing or replacing spark plugs. One such spark plug socket is the Kent-Moore J-39358 spark plug socket. The tool is available from Kent-Moore. For ordering information call 1 -800-345-2233 or write: Kent-Moore SPX Corporation 39784 Little Mack Roseville, MI 48066-2298 Fax: 313-774-9870 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1654 Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ................................................... 0.90 mm (035 in.) Spark Plug Torque ............................................. ......................................................................................................................... 10 - 20 Nm (7 - 15 ft lb) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70% of the highest and no cylinder reading should be less than 689 kPa (100 psi). Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications ROCKER ARM TORQUE Fig. 7 Rocker Arm Cover, Rocker Arms & Pushrod Replacement ^ Rocker Arms are not adjustable on this engine, tighten Rocker Arm Nuts to 30 Nm (22 lbs. ft.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1661 Valve Clearance: Adjustments The Rocker Arms are not adjustable on this engine refer to Rocker Arm / Service and Repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1662 Valve Clearance: Service and Repair The Rocker Arms are not adjustable on this engine refer to Rocker Arm / Service and Repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair Water Pump: Service and Repair Fig. 20 Water Pump Installation 1. Disconnect battery ground cable, then drain cooling system. 2. Remove serpentine drive belt, then the alternator and bracket. 3. Remove water pump pulley attaching bolts, then remove the pulley, Fig. 20. 4. Remove water pump attaching bolts, then the water pump. 5. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information > Page 1671 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information > Page 1672 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information > Page 1673 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information > Page 1674 Coolant: Technical Service Bulletins Cooling System - Use of Recycled Engine Coolant Number: 91-235-6B Section: 6B Date: MARCH 1991 Corporate Bulletin No.: 116201 Subject: USE OF RECYCLED ENGINE COOLANT Model and Year: ALL PASSENGER CARS AND TRUCKS With the current emphasis on environmental issues and disposal of waste, significant attention is being given to the recycling of engine coolant. Many coolant recycling systems are being aggressively marketed today, ranging from very complex distillation (stationary) to straightforward filtration (mobile). As stated in previous service bulletins, General Motors does not endorse the use of recycled engine coolants in our products at this point in time. Recycling engine coolant is a very complex procedure and consequently will require a significant amount of research to determine which of the many processes is acceptable by General Motors. While we understand the growing concern being placed on (spent) engine coolant disposal, it is imperative that the quality of engine coolants being used in General Motors vehicles is not affected in any way. General Motors is addressing the issue of recycled engine coolants for the combined benefit of our dealers, vehicle owners, and the environment. Over the next several months General Motors will conduct an experiment designed to evaluate both distillation and "on-site" recycling processes. The results of this experiment will be provided to all dealers (spring, 1991) and will outline which process(es) is acceptable to General Motors. It is essential that recycled engine coolant not be used in any General Motors products as communicated in previous bulletins. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information > Page 1675 Coolant: Technical Service Bulletins Coolant - Specification/Usage Number: 91-62-6B Section: 6B Date: August 1990 Corp. Bulletin No.: 066202 Subject: COOLANT USAGE Model and Year: ALL 1988-91 PASSENGER CARS AND TRUCKS TO: ALL CHEVROLET DEALERS THIS INFORMATION SUPERSEDES INFORMATION PROVIDED BY GMSPO IN PARTS AND ACCESSORIES BULLETINS IB NO. 90-55 AND 90-60 AND INFORMATION PROVIDED IN VARIOUS TRUCK SERVICE AND OWNERS MANUALS AND SHOULD BE USED TO DETERMINE CORRECT COOLANT USAGE IN LIGHT AND MEDIUM DUTY TRUCK APPLICATIONS. GM coolant specification 6038-M or 1899-M (P/N 1052103) is for use in all light duty trucks with gasoline or diesel engines. This coolant features a low silicate formulation and is intended only for use in engines that have cylinder heads and cylinder blocks made of cast iron. GM coolant specification 1825-M or 6043-M (P/N 1052753) which until recently has been the recommended coolant for light duty trucks has been superseded by GM coolant 6038-M or 1899-M (P/N 1052103) in cast iron truck engines. GM coolant specification 1825-M has a higher silicate formulation which is recommended for all passenger car engines with cylinder heads or cylinder blocks made of aluminum. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information > Page 1676 Coolant: Technical Service Bulletins Coolant - Information on Propylene Glycol Usage File In Section: 6 - Engine Bulletin No.: 43-62-01B Date: April, 1995 Subject: Propylene Glycol Engine Coolant Models: 1994 and Prior Passenger Cars and Trucks This bulletin is being revised to reflect most current information on propylene glycol engine coolant. Please discard Corporate Bulletin Number 4362O1A (Group Reference 6 - Engine). General Motors has been reviewing data supplied on the performance of propylene glycol engine coolant in GM vehicles. It is our conclusion that propylene glycol engine coolant will perform adequately under most vehicle operating conditions. As a result, propylene glycol engine coolant (meeting performance specification GM 1825M) may be used in GM vehicles and will not affect the warranty coverage. Prior to adding propylene glycol engine coolant to the cooling system, all the existing (ethylene glycol) coolant must be removed. This can be accomplished either by utilizing water-based coolant flushing equipment or "waterless quick change" equipment available in the GMDE program. As with any coolant change procedure, be sure to thoroughly purge the heater core and block as well as the radiator before attempting to convert the system to propylene glycol coolant. Freeze/Boil point levels are different for propylene glycol than for ethylene glycol engine coolant. To accurately determine freeze/boil protection level, it is imperative that coolants not be mixed. Removing all the used coolant as previously discussed resolves this concern. Freeze protection of propylene glycol cannot be determined using a standard hydrometer. Rather, a refractometer or test strip must be used. Propylene glycol engine coolants may be recycled in the same manner as conventional ethylene glycol coolant. No adverse effects will be encountered if these coolants are mixed prior to recycling, however, the ratio of propylene glycol coolant to ethylene glycol coolant should be kept low to minimize the effects on freeze point measurements. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Coolant Recycling Information > Page 1677 Coolant: Technical Service Bulletins Cooling System - Reconstituted Anti-Freeze Information Number: 90-49-6B Section: 6B Date: August 1989 Corporate Bulletin No.: 930107 Subject: RECONSTITUTED ANTI-FREEZE Model and Year: ALL MODELS, ALL MODEL YEARS TO: ALL CHEVROLET DEALERS This bulletin provides information on "reconstituted anti-freeze". It has been brought to our attention that a number of manufacturers claim to have the capability of reconstituting engine coolant on site. At this time, General Motors does not endorse this practice or any equipment. Anti-freeze recycling is a very complex issue. In use as an engine coolant, ethylene glycol becomes oxidized producing a very degraded and deteriorated substance. Contamination by other automotive fluids during draining, handling and storage is also a major detriment to the reclaiming process. There is no additive we are aware of that can be merely put into used coolant that will restore it to an acceptable state. Typically, a multi-million dollar facility, utilizing sophisticated technology with distillation capabilities along with appropriate quality control would be required to adequately process used coolant to bring it to GM specifications. Disposal of all chemical products should be done in accordance with all applicable federal, state and local laws and regulations. Review engine coolant substitutes Dealer Service Bulletin No. 89-57-6B, dated January 1989. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Page 1678 Coolant: Specifications MAKE, YEAR & MODEL LITERS QUARTS CHEVROLET CAVALIER 1992 V6 12.4 13.1 1992 4-cyl 8.7 9.2 1991 V6 13.5 14.2 1991 4-cyl 11.1 11.7 1990 V6 10.4 11.0 1990 4-cyl 8.0 8.5 1989-85 4-cyl 9.1 9.6 V6 10.5 11.1 1984-83 All 9.2 9.7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation Some vehicles use a buzzer or indicator lamp to indicate a low coolant level condition. The buzzer or lamp is activated by a sensor, located in the radiator, when the coolant level becomes one quart or more low. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Indicator Lamp > Component Information > Description and Operation > Page 1682 Coolant Level Indicator Lamp: Service and Repair This lamp will be illuminated when engine coolant level in the radiator drops below a pre-determined level. To turn lamp "OFF," check cooling system, then add coolant to bring system to proper level. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Locations Coolant Reservoir: Locations RH Rear Of Engine Compartment. RH Side Of Engine Compartment, In Surge Tank Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1691 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1692 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1693 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1694 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1695 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1696 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1697 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1698 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1699 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1700 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1701 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1702 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1703 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1704 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1705 Radiator Cooling Fan Motor: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1706 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1707 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1708 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1709 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1710 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1711 Radiator Cooling Fan Motor: Electrical Diagrams Cooling Fan (Engine) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1712 Cooling Fan (Engine) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1713 Radiator Cooling Fan Motor: Description and Operation The coolant fan is turned on and off by the ECM based on inputs from the coolant temperature sensor, vehicle speed sensor and the A/C system, if equipped. Battery voltage is applied at all times to terminal 1 of the coolant fan relay and, when the ignition switch is in RUN position, battery voltage is applied to terminal 5 of the relay. The ECM energizes the coolant fan relay by grounding circuit 335. The relay energizes and battery voltage is applied to the coolant fan. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Radiator Cooling Fan Motor: Initial Inspection and Diagnostic Overview System Check 1. With ambient temperature above 70°F, open all doors, start engine and set mode selector, if equipped to MAX. Coolant fan should turn on. 2. With engine coolant below operating temperature, move mode selector to OFF position. Coolant fan should turn off in a short period of time. 3. Run engine at fast idle for several minutes, coolant fan should turn on before coolant temperature indicator comes on or coolant temperature display shows H. 4. Turn ignition switch to Off position, coolant fan should turn off. Troubleshooting Hints 1. On 1990 models, visually inspect HTR/A/C fuse or fuse 16. 2. On 1991-92 models, if coolant fan does not operate, check fusible link L and HTR/A/C fuse. 3. On all models, if coolant fan runs with ignition switch off, replace coolant fan relay. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1716 Radiator Cooling Fan Motor: Component Tests and General Diagnostics Component Diagnostic Charts - TBI Chart C-12 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1717 Wiring Diagram For Cooling Fan CIRCUIT DESCRIPTION: Battery voltage is supplied to terminal "1" in order operate the cooling fan motor. Terminal "5" of the relay has ignition voltage supplied to it. When the ECM grounds circuit 335, the relay and the cooling fan are energized. When the engine is running, the ECM will energize the cooling fan if a Coolant Temperature Sensor (CTS) code is set, or if the following conditions exist. 1. The A/C is "ON." 2. The coolant temperature is greater than 108°C (230°F). DIAGNOSTIC AIDS: 1. If the owner complained of an overheating problem, it must be determined if the complaint was due to an actual boil over, the temperature light, or the temperature gauge indicates overheating. 2. If the gauge or light indicates overheating, but no boilover is detected, the gauge circuit should be checked. The gauge accuracy can also be checked by comparing the coolant sensor reading using a Scan tool and comparing its reading with the gauge reading. 3. If the engine is actually overheating and the gauge indicates overheating, but the cooling fan is not energized, the coolant sensor has probably shifted out of calibration and should be replaced. 4. If the engine is overheating, and the cooling fan is running, the cooling system should be checked for a basic cooling system problem. System Diagnosis Coolant Fan Does Not Turn On 1. Turn ignition switch to RUN position, then ground terminal B (white/black) of ALDL connector. If coolant fan runs, problem is ECM related. 2. If coolant fan does not run, ground terminal C1/21 (VIN G) or C3/E8 (VIN T) of ECM with fused jumper wire. If coolant fan runs, problem is ECM related. 3. If coolant fan does not run, leave terminal grounded as in step 2 and disconnect coolant fan relay connector. Measure voltage from terminal 5 (brown/white) to ground. If no voltage is present, check brown and brown/white wire and HTR/A/C fuse for open. 4. If battery voltage is present, leave terminal grounded as in step 2 and measure voltage between terminals 5 (brown/white) and 2 (dark green/white) of coolant fan relay connector. If no voltage is present, check dark green/white wire for open. 5. If battery voltage is present, measure voltage from terminal 1 (red) of coolant fan relay connector to ground. If no voltage is present, check red wire and fusible link L for open. 6. If battery voltage is present, disconnect coolant fan relay connector and connect a 20 amp fused jumper between terminals 1 (red) and 4 (black/red). If coolant fan runs, replace coolant fan relay. 7. If coolant fan does not run, leave fused jumper in place as in step 6 and disconnect connector from coolant fan. Measure voltage from terminal B (black/red) of coolant fan connector to ground. If no voltage is present, check black/red wire for open. 8. If battery voltage is present, leave fused jumper in place as in step 6 and measure voltage between terminals B (black/red) and A (black) of coolant fan connector. If no voltage is present, check black wire for open. 9. If battery voltage is present, replace coolant fan motor. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1718 Coolant Fan Does Not Turn Off With Engine Cool, A/C Mode Selector Off & Ignition Switch In RUN 1. Turn ignition switch to RUN position, then disconnect coolant fan relay connector and connect test lamp between terminals 5 (brown/white) and 2 (dark green/white) of coolant fan relay connector. If lamp does not light, replace coolant fan relay. 2. If lamp lights, check dark green/white wire for short to ground. If wire is satisfactory, problem is ECM related. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Page 1719 Radiator Cooling Fan Motor: Service and Repair 1. Disconnect battery ground cable. 2. Remove air cleaner duct, then disconnect wiring harness from motor and fan frame. 3. Remove fan assembly from radiator support. 4. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Engine Component Locations. LH Front Of Engine Compartment Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1723 Radiator Cooling Fan Motor Relay: Description and Operation Wiring Diagram For Cooling Fan The ECM controls the engine coolant fan relay under several operating conditions. If the coolant temperature sensor indicates high engine temperature, the ECM will energize the relay to turn "ON" the fan. If the A/C is engaged, the ECM will turn the coolant fan on to cool the condenser as well as the radiator. Some fault codes will cause the ECM to turn on the fan. Above certain vehicle speeds, the ECM will de-energize the fan relay since at higher road speeds there is ample air flow. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Locations Radiator Cooling Fan Temperature Sensor / Switch: Locations LH Front Of 2.2L LH Side Of Engine, Behind Coolant Outlet Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation Fan Clutch: Description and Operation Fig. 1 Typical Variable-Speed Fan Installed Fig. 2 Variable-Speed Fan With Flat Bi-Metal Thermostatic Spring Fig. 3 Variable-Speed Fan With Coiled Bi-Metal Thermostatic Spring The fan drive clutch, Fig. 1, is a fluid coupling containing silicone oil. Fan speed is regulated by the torque-carrying capacity of the silicone oil. The more silicone oil in the coupling the greater the fan speed, and the less silicone oil the slower the fan speed. Two types of fan drive clutches are in use. On one, Fig. 2, a bimetallic-metallic strip and control piston on the front of the fluid coupling regulates the amount of silicone oil entering the coupling. The bimetallic-metallic strip bows outward with an increase in surrounding temperature and allows a piston to move outward. The piston opens a valve regulating the flow of silicone oil into the coupling from a reserve chamber. The silicone oil is returned to the reserve chamber through a bleed hole when the valve is closed. On the other type of fan drive clutch, Fig. 3, a heat-sensitive, bimetallic-metal spring connected to an opening plate brings about a similar result. Both units cause the fan speed to increase with a rise in temperature and to decrease as the temperature goes down. In some cases a Flex-Fan is used instead of a Fan Drive Clutch. Flexible blades vary the volume of air being drawn through the radiator, automatically increasing the pitch at low engine speeds. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation Coolant Temperature Sensor (CTS) The engine coolant temperature sensor is a thermistor that is located in the engine coolant flow. When the coolant temperature is low, the sensor produces a high resistance. When the coolant temperature is high, the sensor produces a low resistance. The computer sends a 5.0 volt signal to the coolant temperature sensor through a resistor in the ECM and measures the voltage. The voltage will be high or low depending on coolant temperature. By varying the voltage, the computer will sense engine coolant temperature. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Locations Radiator Cooling Fan Temperature Sensor / Switch: Locations LH Front Of 2.2L LH Side Of Engine, Behind Coolant Outlet Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Heater Control Valve: > 914131A > Sep > 91 > Heater Low Output Heater Control Valve: Customer Interest Heater - Low Output Number: 91-413-1A Section: 1A Date: SEPT. 1991 Corporate Bulletin No.: 131104 ASE No.: A7 Subject: LOW HEAT DELIVERY RELATED DIAGNOSIS REVISED PROCEDURE Model and Year: 1989-91 CAVALIER On customer comments of low heater output on 1989-91 J cars, before replacing a suspected defective engine cooling thermostat, proper diagnosis of the condition must be performed to avoid the possibility of a repeat repair. Follow "Diagnosis" as shown in Section 1A/1B of the appropriate Service Manual. After completing the diagnosis, use the following as a guide to the next corrective step: ^ If the diagnosis indicates a defective thermostat, refer to Section 6C for replacement. ^ If the diagnosis indicates a defective temperature control cable, refer to Section 1A/1B for replacement. ^ If the diagnosis indicates the temperature control cable is no longer "snapped" into its retainer, refer to "Temperature Control Cable Repair" in the 1991 Service Manual, Sections 1A/1B. ^ If the diagnosis indicates that the temperature control cable is out of adjustment, refer to the following procedure to repair. TEMPERATURE CONTROL CABLE ADJUSTMENT PROCEDURE Condition: 1. "Spring back" off full "hot" temperature control position (or not attaining full "cold" temperature door position). Condition: 2. "Spring back" off full "cold" temperature control position (or not attaining full "hot" temperature door position). Cause: The temperature control cable "clip" needs adjustment. Refer to the illustration for correct gripping of the "clip" during adjustment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Heater Control Valve: > 914131A > Sep > 91 > Heater Low Output > Page 1745 Correction For Number: 1. Grip "clip" at module end of cable while pulling temperature control lever to "hot" position. Correction For Number: 2. Grip "clip" at module end of cable while pushing temperature control lever to "cold" position. NOTICE: FAILURE TO GRIP "CLIP" CORRECTLY WILL DAMAGE ITS ABILITY TO HOLD POSITION ON THE CABLE. THE TEMPERATURE CONTROL CABLE MUST BE REPLACED IF "CLIP" RETENTION FAILS. Verify correct adjustment after repair by observing for no, or very liftle, "spring back" of the temperature control lever and listening for temperature door "slam" when the control lever is moved to full hot and cold positions quickly. Please note your copies of the Service Manuals in Sections 1A and 1B, under "Temperature Control Cable", with these new adjustment instructions. Warranty and Labor Information: Use the appropriate failure code for each occurrence. For thermostat or temperature control cable replacement, use current applicable warranty and labor information. For temperature cable repair at the heater control, use current heater warranty and labor information. For temperature control repair at the HVAC module or cable adjustment: Labor Operation Number: D0400 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Control Valve: > 914131A > Sep > 91 > Heater - Low Output Heater Control Valve: All Technical Service Bulletins Heater - Low Output Number: 91-413-1A Section: 1A Date: SEPT. 1991 Corporate Bulletin No.: 131104 ASE No.: A7 Subject: LOW HEAT DELIVERY RELATED DIAGNOSIS REVISED PROCEDURE Model and Year: 1989-91 CAVALIER On customer comments of low heater output on 1989-91 J cars, before replacing a suspected defective engine cooling thermostat, proper diagnosis of the condition must be performed to avoid the possibility of a repeat repair. Follow "Diagnosis" as shown in Section 1A/1B of the appropriate Service Manual. After completing the diagnosis, use the following as a guide to the next corrective step: ^ If the diagnosis indicates a defective thermostat, refer to Section 6C for replacement. ^ If the diagnosis indicates a defective temperature control cable, refer to Section 1A/1B for replacement. ^ If the diagnosis indicates the temperature control cable is no longer "snapped" into its retainer, refer to "Temperature Control Cable Repair" in the 1991 Service Manual, Sections 1A/1B. ^ If the diagnosis indicates that the temperature control cable is out of adjustment, refer to the following procedure to repair. TEMPERATURE CONTROL CABLE ADJUSTMENT PROCEDURE Condition: 1. "Spring back" off full "hot" temperature control position (or not attaining full "cold" temperature door position). Condition: 2. "Spring back" off full "cold" temperature control position (or not attaining full "hot" temperature door position). Cause: The temperature control cable "clip" needs adjustment. Refer to the illustration for correct gripping of the "clip" during adjustment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Control Valve: > 914131A > Sep > 91 > Heater - Low Output > Page 1751 Correction For Number: 1. Grip "clip" at module end of cable while pulling temperature control lever to "hot" position. Correction For Number: 2. Grip "clip" at module end of cable while pushing temperature control lever to "cold" position. NOTICE: FAILURE TO GRIP "CLIP" CORRECTLY WILL DAMAGE ITS ABILITY TO HOLD POSITION ON THE CABLE. THE TEMPERATURE CONTROL CABLE MUST BE REPLACED IF "CLIP" RETENTION FAILS. Verify correct adjustment after repair by observing for no, or very liftle, "spring back" of the temperature control lever and listening for temperature door "slam" when the control lever is moved to full hot and cold positions quickly. Please note your copies of the Service Manuals in Sections 1A and 1B, under "Temperature Control Cable", with these new adjustment instructions. Warranty and Labor Information: Use the appropriate failure code for each occurrence. For thermostat or temperature control cable replacement, use current applicable warranty and labor information. For temperature cable repair at the heater control, use current heater warranty and labor information. For temperature control repair at the HVAC module or cable adjustment: Labor Operation Number: D0400 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 1756 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 1757 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 1758 Heater Core: Service and Repair Heater Module Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 1759 Heater Module Legend 1. Disconnect battery ground cable and drain cooling system. 2. Raise and support vehicle. 3. Remove rear lateral transaxle strut and mount, if equipped. 4. Disconnect heater case drain tube, then disconnect heater core heater hoses. 5. Lower vehicle and remove right and left hush panels, steering column trim cover and glove compartment. 6. Remove heater duct retaining screw and heater duct. 7. Remove heater core cover attaching screws, then gently pull cover rearward and out of vehicle, Fig. 12. When removing heater core assembly, pull assembly straight toward interior of vehicle until plastic drain tube clears cowl. If assembly is tilted in any direction before tube clears cowl, the drain tube may break. 8. Remove heater core retaining clamps and heater core from case. 9. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation Some vehicles use a buzzer or indicator lamp to indicate a low coolant level condition. The buzzer or lamp is activated by a sensor, located in the radiator, when the coolant level becomes one quart or more low. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Coolant Level Indicator Lamp > Component Information > Description and Operation > Page 1764 Coolant Level Indicator Lamp: Service and Repair This lamp will be illuminated when engine coolant level in the radiator drops below a pre-determined level. To turn lamp "OFF," check cooling system, then add coolant to bring system to proper level. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation This temperature indicating system consists of a sending unit, located on the cylinder head, electrical temperature gauge and an instrument voltage regulator. As engine temperature increases or decreases, the resistance of the sending unit changes, in turn controlling current flow through the gauge. When engine temperature is low sending unit resistance is high, current flow through the gauge is restricted, and the gauge pointer remains against the stop or moves very little. As engine temperature increases sending unit resistance decreases and current flow through the gauge increases, resulting in increased pointer movement. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 1768 Temperature Gauge: Testing and Inspection TEMPERATURE GAUGE INDICATES HOT 1. Disconnect coolant temperature sender connector. 2. Turn ignition switch ON. ^ If gauge indicates HOT, check for short in sender wire or printed circuit board. ^ If gauge indicates COLD, replace coolant temperature sender. TEMPERATURE GAUGE INDICATES COLD 1. Disconnect coolant temperature sender connector. 2. Ground coolant temperature sender wire. Turn ignition switch ON. ^ If gauge indicates COLD, check for open in sender wire or printed circuit board. ^ If gauge indicates HOT, replace coolant temperature sender. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Testing and Inspection Temperature Warning Lamp/Indicator: Testing and Inspection If the red light is not lit when the engine is being cranked, check for a burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when the engine is running, check the wiring between light and switch for a ground, temperature switch defective, or overheated cooling system. As a test circuit to check whether the red bulb is functioning properly, a wire which is connected to the ground terminal of the ignition switch is tapped into its circuit. When the ignition is in the start engine cranking position, the ground terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and the ignition switch is in the on position, the test circuit is opened and the bulb is then controlled by the temperature switch. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Radiator: 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 1776 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 1777 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 1778 Radiator: Technical Service Bulletins Cooling - Radiator Repair/Replacement Guidelines File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-02-017 Date: October, 1999 INFORMATION Subject: Radiator Repair/Replacement Guidelines Models: 2000 and Prior Passenger Cars and Trucks If repair of an aluminum/plastic radiator is required, it is recommended that the following guidelines be followed: For Vehicles Under Warranty For aluminum/plastic radiators that have damage to the face of the core including bent fins, punctures, cuts, leaking tubes or header tubes, the aluminum radiator core section should be replaced with a new one. In these cases, if both of the plastic tanks are not damaged, they can be reused with the new core. If one or both of the plastic tanks are damaged along with the core, it is recommended that a complete new radiator assembly be installed. Warranty repairs for leaks at the tank to header (gasket leaks), broken/cracked plastic tanks, cross threaded or leaking oil coolers should be repaired without replacing the complete radiator. This type of repair should be handled by the radiator repair facility in your area. Many of these radiator repair facilities are members of the National Automotive Radiator Service Association (NARSA) who follow industry and General Motors guidelines when repairing radiators. These facilities have the special tools, tanks and pressurizing equipment needed to properly test the repaired radiator prior to returning it to the dealership. Many of these facilities receive the repair components directly from General Motors. The sublet expense for a new radiator or the repair of the radiator under warranty should be handled following normal procedures. For Vehicles No Longer Under Warranty The GM released epoxy repair kit referenced in previous publications is no longer available. Repairs to the radiator, rather than replacement, is strictly at the owner's discretion. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications VIN G, Relief Pressure VIN G, Relief Pressure Radiator Cap Relief Pressure 15 psi Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Engine Component Locations. LH Front Of Engine Compartment Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1786 Radiator Cooling Fan Motor Relay: Description and Operation Wiring Diagram For Cooling Fan The ECM controls the engine coolant fan relay under several operating conditions. If the coolant temperature sensor indicates high engine temperature, the ECM will energize the relay to turn "ON" the fan. If the A/C is engaged, the ECM will turn the coolant fan on to cool the condenser as well as the radiator. Some fault codes will cause the ECM to turn on the fan. Above certain vehicle speeds, the ECM will de-energize the fan relay since at higher road speeds there is ample air flow. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation Coolant Temperature Sensor (CTS) The engine coolant temperature sensor is a thermistor that is located in the engine coolant flow. When the coolant temperature is low, the sensor produces a high resistance. When the coolant temperature is high, the sensor produces a low resistance. The computer sends a 5.0 volt signal to the coolant temperature sensor through a resistor in the ECM and measures the voltage. The voltage will be high or low depending on coolant temperature. By varying the voltage, the computer will sense engine coolant temperature. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Locations Radiator Cooling Fan Temperature Sensor / Switch: Locations LH Front Of 2.2L LH Side Of Engine, Behind Coolant Outlet Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation This temperature indicating system consists of a sending unit, located on the cylinder head, electrical temperature gauge and an instrument voltage regulator. As engine temperature increases or decreases, the resistance of the sending unit changes, in turn controlling current flow through the gauge. When engine temperature is low sending unit resistance is high, current flow through the gauge is restricted, and the gauge pointer remains against the stop or moves very little. As engine temperature increases sending unit resistance decreases and current flow through the gauge increases, resulting in increased pointer movement. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 1798 Temperature Gauge: Testing and Inspection TEMPERATURE GAUGE INDICATES HOT 1. Disconnect coolant temperature sender connector. 2. Turn ignition switch ON. ^ If gauge indicates HOT, check for short in sender wire or printed circuit board. ^ If gauge indicates COLD, replace coolant temperature sender. TEMPERATURE GAUGE INDICATES COLD 1. Disconnect coolant temperature sender connector. 2. Ground coolant temperature sender wire. Turn ignition switch ON. ^ If gauge indicates COLD, check for open in sender wire or printed circuit board. ^ If gauge indicates HOT, replace coolant temperature sender. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Testing and Inspection Temperature Warning Lamp/Indicator: Testing and Inspection If the red light is not lit when the engine is being cranked, check for a burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when the engine is running, check the wiring between light and switch for a ground, temperature switch defective, or overheated cooling system. As a test circuit to check whether the red bulb is functioning properly, a wire which is connected to the ground terminal of the ignition switch is tapped into its circuit. When the ignition is in the start engine cranking position, the ground terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and the ignition switch is in the on position, the test circuit is opened and the bulb is then controlled by the temperature switch. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Customer Interest for Thermostat: > 914131A > Sep > 91 > Heater Low Output Thermostat: Customer Interest Heater - Low Output Number: 91-413-1A Section: 1A Date: SEPT. 1991 Corporate Bulletin No.: 131104 ASE No.: A7 Subject: LOW HEAT DELIVERY RELATED DIAGNOSIS REVISED PROCEDURE Model and Year: 1989-91 CAVALIER On customer comments of low heater output on 1989-91 J cars, before replacing a suspected defective engine cooling thermostat, proper diagnosis of the condition must be performed to avoid the possibility of a repeat repair. Follow "Diagnosis" as shown in Section 1A/1B of the appropriate Service Manual. After completing the diagnosis, use the following as a guide to the next corrective step: ^ If the diagnosis indicates a defective thermostat, refer to Section 6C for replacement. ^ If the diagnosis indicates a defective temperature control cable, refer to Section 1A/1B for replacement. ^ If the diagnosis indicates the temperature control cable is no longer "snapped" into its retainer, refer to "Temperature Control Cable Repair" in the 1991 Service Manual, Sections 1A/1B. ^ If the diagnosis indicates that the temperature control cable is out of adjustment, refer to the following procedure to repair. TEMPERATURE CONTROL CABLE ADJUSTMENT PROCEDURE Condition: 1. "Spring back" off full "hot" temperature control position (or not attaining full "cold" temperature door position). Condition: 2. "Spring back" off full "cold" temperature control position (or not attaining full "hot" temperature door position). Cause: The temperature control cable "clip" needs adjustment. Refer to the illustration for correct gripping of the "clip" during adjustment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Customer Interest for Thermostat: > 914131A > Sep > 91 > Heater Low Output > Page 1810 Correction For Number: 1. Grip "clip" at module end of cable while pulling temperature control lever to "hot" position. Correction For Number: 2. Grip "clip" at module end of cable while pushing temperature control lever to "cold" position. NOTICE: FAILURE TO GRIP "CLIP" CORRECTLY WILL DAMAGE ITS ABILITY TO HOLD POSITION ON THE CABLE. THE TEMPERATURE CONTROL CABLE MUST BE REPLACED IF "CLIP" RETENTION FAILS. Verify correct adjustment after repair by observing for no, or very liftle, "spring back" of the temperature control lever and listening for temperature door "slam" when the control lever is moved to full hot and cold positions quickly. Please note your copies of the Service Manuals in Sections 1A and 1B, under "Temperature Control Cable", with these new adjustment instructions. Warranty and Labor Information: Use the appropriate failure code for each occurrence. For thermostat or temperature control cable replacement, use current applicable warranty and labor information. For temperature cable repair at the heater control, use current heater warranty and labor information. For temperature control repair at the HVAC module or cable adjustment: Labor Operation Number: D0400 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat: > 914131A > Sep > 91 > Heater - Low Output Thermostat: All Technical Service Bulletins Heater - Low Output Number: 91-413-1A Section: 1A Date: SEPT. 1991 Corporate Bulletin No.: 131104 ASE No.: A7 Subject: LOW HEAT DELIVERY RELATED DIAGNOSIS REVISED PROCEDURE Model and Year: 1989-91 CAVALIER On customer comments of low heater output on 1989-91 J cars, before replacing a suspected defective engine cooling thermostat, proper diagnosis of the condition must be performed to avoid the possibility of a repeat repair. Follow "Diagnosis" as shown in Section 1A/1B of the appropriate Service Manual. After completing the diagnosis, use the following as a guide to the next corrective step: ^ If the diagnosis indicates a defective thermostat, refer to Section 6C for replacement. ^ If the diagnosis indicates a defective temperature control cable, refer to Section 1A/1B for replacement. ^ If the diagnosis indicates the temperature control cable is no longer "snapped" into its retainer, refer to "Temperature Control Cable Repair" in the 1991 Service Manual, Sections 1A/1B. ^ If the diagnosis indicates that the temperature control cable is out of adjustment, refer to the following procedure to repair. TEMPERATURE CONTROL CABLE ADJUSTMENT PROCEDURE Condition: 1. "Spring back" off full "hot" temperature control position (or not attaining full "cold" temperature door position). Condition: 2. "Spring back" off full "cold" temperature control position (or not attaining full "hot" temperature door position). Cause: The temperature control cable "clip" needs adjustment. Refer to the illustration for correct gripping of the "clip" during adjustment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat: > 914131A > Sep > 91 > Heater - Low Output > Page 1816 Correction For Number: 1. Grip "clip" at module end of cable while pulling temperature control lever to "hot" position. Correction For Number: 2. Grip "clip" at module end of cable while pushing temperature control lever to "cold" position. NOTICE: FAILURE TO GRIP "CLIP" CORRECTLY WILL DAMAGE ITS ABILITY TO HOLD POSITION ON THE CABLE. THE TEMPERATURE CONTROL CABLE MUST BE REPLACED IF "CLIP" RETENTION FAILS. Verify correct adjustment after repair by observing for no, or very liftle, "spring back" of the temperature control lever and listening for temperature door "slam" when the control lever is moved to full hot and cold positions quickly. Please note your copies of the Service Manuals in Sections 1A and 1B, under "Temperature Control Cable", with these new adjustment instructions. Warranty and Labor Information: Use the appropriate failure code for each occurrence. For thermostat or temperature control cable replacement, use current applicable warranty and labor information. For temperature cable repair at the heater control, use current heater warranty and labor information. For temperature control repair at the HVAC module or cable adjustment: Labor Operation Number: D0400 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Page 1817 Thermostat: Specifications VIN G, Opening Temperature VIN G, Opening Temperature Thermostat Opening Temperature 195 F Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > Thermostat Check Thermostat Troubleshooting Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > Thermostat Check > Page 1820 Thermostat Troubleshooting Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > Page 1821 Thermostat: Service and Repair Fig. 21 Thermostat & Housing Assembly Refer to Fig. 21 when performing the following procedure. 1. Disconnect battery negative cable. 2. Remove air intake duct. 3. With engine cool, drain engine coolant below thermostat level. Never open cooling system with engine hot. Failure to follow this warning may cause personal injury. 4. Disconnect radiator hose from thermostat housing. 5. Remove thermostat housing retaining nuts, then the housing, gasket and thermostat. 6. Reverse procedure to install noting the following: a. Prior to installation, ensure thermostat gasket area is thoroughly clean. b. Install thermostat with new gasket. c. Torque thermostat housing retaining nuts to 89 inch lbs. d. Refill and bleed cooling system as needed. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair Water Pump: Service and Repair Fig. 20 Water Pump Installation 1. Disconnect battery ground cable, then drain cooling system. 2. Remove serpentine drive belt, then the alternator and bracket. 3. Remove water pump pulley attaching bolts, then remove the pulley, Fig. 20. 4. Remove water pump attaching bolts, then the water pump. 5. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation Converter Types PRECAUTIONS CAUTION: Prolonged operation with a misfiring or flooded engine may cause the converter to overheat. This could cause damage either to the catalyst itself or the operating vehicle and possible personal injury. NOTICE: When jacking or lifting vehicle from frame side rails, be certain lift pads do not contact catalytic converter otherwise damage to converter may result. SYSTEM DESCRIPTION The catalytic converter is an emission control device added to the exhaust system to effectively reduce the levels of carbon monoxide, hydrocarbons, and in some cases oxides of nitrogen, exiting the tailpipe. The converter allows for a faster chemical reaction to take place and although it enters into the chemical reaction, it remains unchanged, ready to repeat Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1829 the process. This device sometimes requires the use of heat shields, due to its high operating temperatures. The heat shields are necessary to protect chassis components, passenger compartment, and other areas from heat related damage. General Motors uses four different converter designs in conjunction with two types of catalysts. The four converter designs are: 1. Single bed monolith 2. Dual bed monolith 3. Single bed pellet 4. Dual bed pellet The two types of catalysts used are an Oxidation catalyst and a Three-Way (Oxidation/Reduction) catalyst. The Oxidation catalyst is coated with a material containing platinum and palladium which lowers levels of carbon monoxide and hydrocarbons. The Three-Way (Oxidation/Reduction) catalyst is coated with platinum and rhodium which lowers levels of oxides of nitrogen (NOx), as well as carbon monoxide and hydrocarbons. All dual bed converters, whether monolith or pellet type, contain both oxidation and three-way catalysts. A small diameter fuel tank filler neck is used on catalytic converter equipped vehicles to prevent the use of leaded fuel pump nozzles. Since the use of leaded fuels, or fuel additives containing lead, contaminates (damages) the catalysts, the use of unleaded fuels is mandatory on catalytic converter equipped vehicles. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1830 Catalytic Converter: Testing and Inspection Proper diagnosis for a restricted exhaust system is essential before any components are replaced. The following procedure(s) may be used for diagnosis: Exhaust System Test at Oxygen Sensor CHECK AT 02 SENSOR: 1. Carefully remove O2 sensor. 2. Install Exhaust Backpressure Tester in place of 02 sensor. 3. After completing the diagnosis described below, be sure to coat threads of 02 sensor with anti-seize compound prior to re-installation. DIAGNOSIS: 1. With the engine idling at normal operating temperature, observe the exhaust system back pressure reading on the gauge. The reading should not exceed 1.25 psi (8.6 kPa). Increase engine speed to 2000 rpm and observe gauge. The reading should not exceed 3 psi (20.7 kPa). 2. If the back pressure exceeds the given specifications, a restricted exhaust system is indicated. 3. Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffler failure. 4. If there are no obvious reasons for the excessive backpressure, a restricted catalytic converter should be suspected, and replaced. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair Exhaust Manifold: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect oxygen sensor lead, then remove serpentine belt. 3. Remove alternator and position aside. 4. Raise and support vehicle. 5. Disconnect exhaust pipe from the exhaust manifold, then lower the vehicle. 6. Remove exhaust manifold attaching bolts and oil fill tube, then remove exhaust manifold. 7. Reverse procedure to install, torque manifold retaining bolts to specifications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 1841 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 1842 Engine Control Module: Technical Service Bulletins ECM/PCM - Damage Prevention Number: 91-318-6E Section: 6E Date: MAY 1991 Corp. Bulletin No.: 176502R Subject: DAMAGE TO ECM/PCM CIRCUIT BOARD WHEN INSTALLING A MEM-CAL Model and Year: 1986-91 ALL PASSENGER CARS AND TRUCKS CONDITION: When installing a service replacement ECM/PCM, the use of incorrect MEMCAL installation procedures may cause the ECM/PCM to fail before it can be installed in the vehicle. This condition may appear as if the ECM/PCM were defective when it was shipped to the dealership, when in fact it was damaged while being installed. In addition this condition may also occur when installing an "updated" service MEM-CAL into the vehicles original equipment ECM/PCM. CAUSE: Excessive vertical force may be applied to the MEM-CAL resulting in flexing of the circuit board and damage to the connections between the circuit board and attached components. Excessive verticle force may be generated in two ways. 1. Incorrect MEM-CAL installation procedure. 2. Interference between MEM-CAL and cover. CORRECTION: Use the following procedure. Service Procedure: Important: This procedure supersedes any instructions regarding MEM-CAL installation dated prior to September 1990. 1. Inspect the MEM-CAL to determine if a cork spacer is glued to the top side of the MEM-CAL assembly. If so, remove it prior to installation. 2. Align small notches with matching notches in the ECM/PCM MEM-CAL socket. 3. VERY GENTLY press down on the ends of the MEM-CAL until the locking levers are rotated toward the sides of the MEM-CAL. Notice: To avoid ECM/PCM damage, do not press on the ends of the MEM-CAL until the levers snap into place. Do not use any vertical force beyond the minimum required to engage the MEM-CAL into its socket. 4. While continuing light pressure on the ends of MEM-CAL, use your index fingers to press the locking levers inward until they are snapped into place. Listen for click. 5. Install MEM-CAL cover and install ECM/PCM in vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 1843 Engine Control Module: Technical Service Bulletins ECM/PCM - Damaged and/or Misdiagnosed Number: 91-384-6E Section: 6E Date: AUGUST 1991 Corporate Bulletin No.: 176503 Subject: DAMAGED ECM/PCM AND/OR MIS-DIAGNOSED ECM/PCM SYMPTOMS DUE TO INCORRECT "TAP-TESTING" PROCEDURES Model and Year: 1982-91 ALL PASSENGER CARS AND TRUCKS CONDITION: Because of the intermittent nature of some Electronic Control Module (ECM) or Powertrain Control Modules (PCM) symptoms, some service technicians have been subjecting the ECM/PCM to vibration and/or shock testing. Commonly known as tap-testing, this procedure involves tapping on the ECM/PCM case, while the engine is running. It is generally accepted that if the engine or ECM/PCM falters due to the tapping, an intermittent internal ECM/PCM defect may be indicated. However, this may not always be true. If too much force is applied to the ECM/PCM during the test the following symptoms may result: ^ Immediate ECM/PCM failure. ^ ECM/PCM suffers damage which may cause a failure at a later date. ^ ECM/PCM Reset (or Glitch), creating a momentary stall, miss Service Engine Soon (SES) light and/or loss of serial data. CAUSE: The ECM/PCM should be tapped using only the fingertips of one hand. Use of the palm, fist, or any type of tool subjects the ECM/PCM to forces that can cause both the circuit board and the outer aluminum case to flex and distort beyond design limits. The Integrated Circuits (IC) used in today's ECM/PCMs are mounted to the circuit board using a mounting process referred to as "surface technology." There are no circuit board holes for IC leads to go through. The IC leads set on pads, (28 pads or 52 pads depending on the IC) and solder is flowed around the leads to make the electrical connection to the circuit board. ^ Any flexing of the circuit board, beyond design limits, places the IC solder connections at risk of damage. Such damage may be apparent immediately, or it may appear at a future date. Circuit board deflection can occur as a result of striking the ECM/PCM, using ONLY THE PALM OF THE HAND. ^ If struck on the bottom side (the side opposite the service label), the ECM/PCM's aluminum outer case may deflect inward far enough to contact the electrical leads attached to the circuit board. Once in contact with the case the ECM/PCM electrical components will be shorted directly to ground. Although such shorting certainly has the potential to damage the ECM/PCM, it may not be permanent damage, depending on which circuit is involved. However, even if permanent damage is avoided, a short on any of the circuits will cause a disruption of normal ECM/PCM operation for the instant that the short occurs. This disruption may cause the ECM/PCM to reset (see "reset" above), creating the false impression that it is vibration sensitive or faulty. Reset is the ECM/PCM's normal way of coping with large voltage spikes. An ECM/PCM reset does not indicate that the ECM/PCM is defective or faulty, only that it is being subjected to abnormal conditions. CORRECTION: 1. TAP THE ECM/PCM ONLY ON THE TOP SIDE (The top side is where the service label is located.) ^ This will minimize the chance of deflecting the ECM/PCM case into the electrical leads on the circuit board. The clearance between the case and the circuit board is closest on the bottom side of the ECM/PCM. 2. TAP THE ECM/PCM USING ONLY THE FINGERTIPS - NO TOOLS. ^ To avoid excessive case deflection, avoid tapping in the center of the case. Tapping close to the edge of the ECM/PCM, especially in the corners, is best. ^ While using greater force may seem more effective, the test itself may cause the ECM/PCM to fail. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications Engine Control Module: Specifications Computer Terminal Voltage Specifications ECM Connector Terminal End View WIRE COLOR ABBREVIATION BLACK BLK Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 1846 BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 1847 Engine Control Module: Specifications ECM Terminal Identification & Voltage Specifications ECM Connector Terminal End View WIRE COLOR ABBREVIATION BLACK BLK Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 1848 BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 1849 ECM Connector Terminal End View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications > Page 1850 ECM Located In Passenger Compartment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications > Page 1851 ECM Connector Terminal End View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Electronic Control Module (ECM) Engine Control Module: Description and Operation Electronic Control Module (ECM) Closed Loop Operation ECM And PROM Access Cover The Electronic Control Module (ECM) is located in the passenger compartment and is the control center of the Computer Command Control (C3) system. The ECM constantly receives information from various sensors. The computer performs the diagnostic functions of the system. The computer can recognize operational problems and alert the driver through the "SERVICE ENGINE SOON" light. The computer stores a trouble code which identifies the problem area to diagnose and repair. The computer is designed to process the various input information, and send the necessary electrical response to control fuel delivery, spark control, and other emission control systems. The computer used in these vehicles is a type called GMP4. The computer can control these devices through the use of Quad Driver Modules (QDM). When the ECM is commanding a device or a component "ON," the voltage potential of the output is "LOW" or near zero volts. When the ECM is commanding a device or component "OFF," the voltage potential of the circuit will be "HIGH," or near 12 volts. The primary function of the QDM is to supply the ground for the component being controlled. The input information has an interrelation between sensor output. If one of the input devices failed, such as the oxygen sensor, this could affect more than one of the systems controlled by the computer. The computer has a learning ability which allows it to make corrections for minor variations in the fuel system to improve driveability. If the battery is disconnected to clear trouble codes or for repair, the learning process has to begin all over again, and a change may be noticed in the driving performance of the vehicle. To reset the vehicles learning ability, make sure the engine is at operating temperature and operate the vehicle at part throttle, moderate acceleration, and idle conditions, until normal performance returns. The ECM used in these vehicles uses an ECM with two serviceable parts. A controller called a ECM, without a PROM, and a PROM with specific programming information. NOTE: When a production ECM is replaced with a service ECM, it is important to transfer the broadcast code and production number from the original ECM to the service ECM. This allows for positive identification of ECM parts throughout the service life of the vehicle. DO NOT affix the information to the ECM cover. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Electronic Control Module (ECM) > Page 1854 Engine Control Module: Description and Operation Throttle Body Fuel Injection Control Modules Powertrain Control Module (PCM) The Electronic Control Module (ECM) is located in the passenger compartment and is the control center of the Computer Command Control (C3) system. The ECM constantly receives information from various sensors. The computer performs the diagnostic functions of the system. The computer can recognize operational problems and alert the driver through the "SERVICE ENGINE SOON" light. The computer stores a trouble code which identifies the problem area to diagnose and repair. The computer is designed to process the various input information, and send the necessary electrical response to control fuel delivery, spark control, and other emission control systems. The computer can control these devices through the use of Quad Driver Modules (QDM). When the ECM is commanding a device or a component "ON," the voltage potential of the output is "LOW" or near zero volts. When the ECM is commanding a device or component "OFF," the voltage potential of the circuit will be "HIGH," or near 12 volts. The primary function of the QDM is to supply the ground for the component being controlled. The input information has an interrelation between sensor output. If one of the input devices failed, such as the oxygen sensor, this could affect more than one of the systems controlled by the computer. The computer has a learning ability which allows it to make corrections for minor variations in the fuel system to improve driveability. If the battery is disconnected to clear trouble codes or for repair, the learning process has to begin all over again, and a change may be noticed in the driving performance of the vehicle. To reset the vehicles learning ability, make sure the engine is at operating temperature and operate the vehicle at part throttle, moderate acceleration, and idle conditions, until normal performance returns. A vehicle equipped with a 4-cylinder engine has an ECM referred to as GMP4 with two parts for service. A controller which is the ECM itself, without a MEM-CAL, and a memory calibration unit called a MEM-CAL (PROM). Vehicles with a V-6 or V-8 cylinder engine have an ECM referred to as GMCM with three serviceable parts. A controller called a ECM, without a PROM, a PROM with specific programming information, and a CAL-PAK with specific engine specifications. NOTE: When a production ECM is replaced with a service ECM, it is important to transfer the broadcast code and production number from the original ECM to the service ECM. This allows for positive identification of ECM parts throughout the service life of the vehicle. DO NOT affix the information to the ECM cover. C3 Self Diagnostics ALDL Connector Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Electronic Control Module (ECM) > Page 1855 Use a "Scan" tool or ground the diagnostic test terminal with the engine not running and the ignition switch in the "ON" position in order to retrieve codes. The "SERVICE ENGINE SOON" light will flash a Code 12 three times and then flash each code stored in memory three times, if the "Scan" tool is not used. Once all Codes are retrieved, a Code 12 will follow. New codes cannot be stored in the ECM once the diagnostics mode is activated. See DIAGNOSTIC CIRCUIT CHECK for a complete system check. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics Some control module's may have problems due to cracked solder joints on the circuit board. These internal control module problems can cause the following symptoms: ^ Failure to start or vehicle is stalling. ^ The "CHECK ENGINE" "SERVICE ENGINE SOON" or "MALFUNCTION INDICATOR" light will flash or light up, but no trouble codes will be present. ^ Vehicle instrument panel displays may be inoperative. ^ The control module may or may not communicate with the scanner. ^ Other intermittent driveability problems. Incorrect PROM or MEMCAL removal and replacement can create solder joint problems or aggravate an existing condition. See PROM or MEMCAL INSTALLATION for proper procedures. If a solder joint problem results in a "hard" failure, normal test procedures will usually pinpoint a faulty control module. Many symptoms caused by poor solder joints in the control module result in intermittent problems, but they may be hard to duplicate during troubleshooting. Control module's with solder joint problems are sensitive to heat and vibration. You can check for these internal control module problems in either, or both, of the following ways: ^ Remove the control module from its mounting bracket and extend it on the harness so that you can expose it to the vehicle heater ducts. Alternatively, use flexible ducting to route air from the heater to the control module location. Then run the engine and operate the heater at the "MAX HEAT" position. This exposes the control module to approximately 140°F. ^ With the engine running, tap on the control module several times with your hand or finger tips to simulate vehicle vibration. If the engine stumbles or stalls, the "CHECK ENGINE" "SERVICE ENGINE SOON" or "MALFUNCTION INDICATOR" light flashes, or any of the previous symptoms occur, the control module may have bad solder joints on the circuit board. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) Replacement Engine Control Module: Service and Repair Engine Control Module (ECM) Replacement ECM Located In Passenger Compartment. ECM And PROM Access Cover Prom Removal And Tool Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) Replacement > Page 1860 When replacing a production ECM with a service ECM, transfer the broadcast code and production number from the production unit to the service unit. Also, during replacement, the PROM must be removed from the ECM being replaced and transferred to the new unit. Some ECM's are equipped with another chip called a Cal-Pak. If the ECM if equipped with a Cal-Pak chip, it will be located next to the PROM and must be transferred along with the PROM. 1. Disconnect battery ground cable. 2. Then disconnect two computer electrical connectors. 3. Remove computer mounting hardware. 4. Remove computer from passenger compartment. 5. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) Replacement > Page 1861 Engine Control Module: Service and Repair Throttle Body Fuel Injection ECM Replacement When replacing a production ECM with a service ECM, transfer the broadcast code and production number from the production unit to the service unit. Also, during replacement, the PROM, CALPACK and if equipped, the MEMCAL must be removed from the ECM being replaced and transferred to the new unit. Refer to PROM, CALPAK, and MEMCAL for procedures. 1. Disconnect battery ground cable. 2. Then disconnect computer electrical connectors. 3. Remove computer mounting hardware. 4. Remove computer from passenger compartment. 5. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay And In-line Fuse. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1866 Fuel Pump Relay: Description and Operation Wiring Diagram For Fuel Pump Relay When the key is first turned ON, without the engine running, the ECM will turn the fuel pump relay ON for two seconds. This builds up the fuel pressure to normal operating pressure. If the engine is not started within two seconds, the ECM will shut the fuel pump OFF and wait until ignition reference pulses are present. As soon as the engine is cranked, the ECM turns the relay ON, which powers the fuel pump. The ECM continues to power the fuel pump during engine operation. If the fuel pump relay fails, it is backed up by the oil pressure switch, which continues to operate the fuel pump as long as oil pressure remains above 28.0 kPa (4 psi). - A faulty fuel pump relay can result in long cranking times, particularly if the engine is cold. - An inoperative fuel pump would cause a no start condition. A fuel pump which does not provide enough pressure can result in poor performance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1867 Fuel Pump Relay: Testing and Inspection Wiring Diagram For Fuel Pump Relay When the key is first turned ON, without the engine running, the ECM will turn the fuel pump relay ON for two seconds. This builds up the fuel pressure to normal operating pressure. If the engine is not started within two seconds, the ECM will shut the fuel pump OFF and wait until ignition reference pulses are present. As soon as the engine is cranked, the ECM turns the relay ON, which powers the fuel pump. The ECM continues to power the fuel pump during engine operation. If the fuel pump relay fails, it is backed up by the oil pressure switch, which continues to operate the fuel pump as long as oil pressure remains above 28.0 kPa (4 psi). - A faulty fuel pump relay can result in long cranking times, particularly if the engine is cold. - An inoperative fuel pump would cause a no start condition. A fuel pump which does not provide enough pressure can result in poor performance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1868 Fuel Pump Relay: Service and Repair Fuel Pump Relay And In-line Fuse. NOTE: The fuel pump relay is located in the engine compartment, attached to the relay bracket mounted on the dash. Other than checking for loose connections the only service on the fuel pump relay is replacement. PROCEDURE 1. Verify that the ignition switch is in the "OFF" position. 2. Disconnect the wiring harness plug. 3. Remove the fuel pump relay. 4. Install the new fuel pump relay. 5. Connect the wiring harness plug securely. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set Ignition Control Module: Customer Interest Engine - Stalls/No Start/Runs Rough/Code 42 Set Number: 91-453-6D Section: 6D Date: NOV. 1991 Corporate Bulletin No.: 136405 ASE No.: A6, A8 Subject: INTERMITTENT DIAGNOSTIC TROUBLE CODE 42 AND/OR DRIVEABILITY Model and Year: 1990-91 CAVALIER, CORSICA AND BERETTA WITH 2.2L ENGINE Condition: Some 1990-91 J and L vehicles equipped with the 2.2L (LM3) engine may intermittently exhibit one or more of the following conditions: * ECM Diagnostic Trouble Code 42 set, with no trouble found. * Engine stalling rough running, with no trouble found. * Intermittent no-start, with no trouble found. * ECM fuse blown, with no trouble found. Cause: DIS (Ignition) module lead wiring may be subject to a rub-through condition at the engine wiring harness bracket where it is mounted at the transaxle case. In addition, a similar condition may also exist on the transaxle case near the same location, from a sharp edge formed during case casting, when equipped with manual transaxle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 1878 Correction: Refer to Illustrations for location of repairs. Repair Procedure: - Remove secondary ignition wire bracket and wires, set aside. - Remove clutch cable retainer and cables, set aside. (Manual transaxle only.) - Un-clip engine wiring harness conduit from retainer, pull back conduit to expose harness. - Using common "black" electrical tape (locally attained part), begin taping approximately 5 inches back from the point where the main harness breaks out into 3 smaller harnesses. - While taping to the break-out point, push the individual smaller conduits back and tape up the harnesses as far as possible. * IMPORTANT: Tape wire harness with 4 layers of tape to insure proper insulation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 1879 * IMPORTANT: If any wires are worn through enough to short out against each other, if strands of wire are broken, or if an "open" wiring condition is found, refer to Section 8A of the applicable Service Manual for proper wiring repair. - Install wiring harness back into conduit. Before clipping retainer closed, pull the harness towards the center of the vehicle to remove any slack in the harness. This will keep the harness off the transaxle case and away from the transaxle controls. - Clip harness retainer into position. - Reinstall clutch cables and retainer. (Manual transaxle only). - Reinstall secondary ignition cables and bracket. Warranty and Labor Time Information: For taping and repositioning harness: Labor Code: T1789 Labor Time: 0.3 Hours For wiring repair, taping and repositioning of harness: Labor Code: T1789 Labor Time 0.4 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set Ignition Control Module: All Technical Service Bulletins Engine - Stalls/No Start/Runs Rough/Code 42 Set Number: 91-453-6D Section: 6D Date: NOV. 1991 Corporate Bulletin No.: 136405 ASE No.: A6, A8 Subject: INTERMITTENT DIAGNOSTIC TROUBLE CODE 42 AND/OR DRIVEABILITY Model and Year: 1990-91 CAVALIER, CORSICA AND BERETTA WITH 2.2L ENGINE Condition: Some 1990-91 J and L vehicles equipped with the 2.2L (LM3) engine may intermittently exhibit one or more of the following conditions: * ECM Diagnostic Trouble Code 42 set, with no trouble found. * Engine stalling rough running, with no trouble found. * Intermittent no-start, with no trouble found. * ECM fuse blown, with no trouble found. Cause: DIS (Ignition) module lead wiring may be subject to a rub-through condition at the engine wiring harness bracket where it is mounted at the transaxle case. In addition, a similar condition may also exist on the transaxle case near the same location, from a sharp edge formed during case casting, when equipped with manual transaxle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 1885 Correction: Refer to Illustrations for location of repairs. Repair Procedure: - Remove secondary ignition wire bracket and wires, set aside. - Remove clutch cable retainer and cables, set aside. (Manual transaxle only.) - Un-clip engine wiring harness conduit from retainer, pull back conduit to expose harness. - Using common "black" electrical tape (locally attained part), begin taping approximately 5 inches back from the point where the main harness breaks out into 3 smaller harnesses. - While taping to the break-out point, push the individual smaller conduits back and tape up the harnesses as far as possible. * IMPORTANT: Tape wire harness with 4 layers of tape to insure proper insulation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 1886 * IMPORTANT: If any wires are worn through enough to short out against each other, if strands of wire are broken, or if an "open" wiring condition is found, refer to Section 8A of the applicable Service Manual for proper wiring repair. - Install wiring harness back into conduit. Before clipping retainer closed, pull the harness towards the center of the vehicle to remove any slack in the harness. This will keep the harness off the transaxle case and away from the transaxle controls. - Clip harness retainer into position. - Reinstall clutch cables and retainer. (Manual transaxle only). - Reinstall secondary ignition cables and bracket. Warranty and Labor Time Information: For taping and repositioning harness: Labor Code: T1789 Labor Time: 0.3 Hours For wiring repair, taping and repositioning of harness: Labor Code: T1789 Labor Time 0.4 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 1887 Ignition Control Module: Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 1888 Ignition Control Module: Description and Operation Coil Assembly The DIS module monitors the crank sensor signals and based on these signals sends a reference signal to the ECM so that correct spark and fuel injector control can be maintained during all driving conditions. During cranking, the DIS module monitors the "sync pulse" to begin the ignition firing sequence, and below 400 rpm the module controls spark advance by triggering each of the three coils at a pre-determined interval based on engine speed only. Above 400 rpm, the ECM controls the spark timing through the module (EST), and compensates for all driving conditions. The DIS module must receive a "sync pulse" and then a crank signal in that order to enable the engine to start. The DIS module is not repairable. When a module is replaced, the remaining DIS module components must be transferred to the new module. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 1889 Ignition Control Module: Service and Repair Coil Assembly Remove or Disconnect 1. Negative battery cable. 2. DIS assembly from engine. 3. Coils from assembly. 4. Module from assembly plate. Install or Connect 1. Module to assembly plate. (Carefully engage sensor to module terminals.) 2. Coils. 3. DIS assembly to engine. 4. Negative battery cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation Coolant Temperature Sensor (CTS) The engine coolant temperature sensor is a thermistor that is located in the engine coolant flow. When the coolant temperature is low, the sensor produces a high resistance. When the coolant temperature is high, the sensor produces a low resistance. The computer sends a 5.0 volt signal to the coolant temperature sensor through a resistor in the ECM and measures the voltage. The voltage will be high or low depending on coolant temperature. By varying the voltage, the computer will sense engine coolant temperature. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 1899 Crankshaft Position Sensor: Mechanical Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1900 Rear Of Engine Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1901 Crankshaft Position Sensor: Description and Operation Typical DIS Crankshaft Sensor This crankshaft sensor is mounted remotely on the bottom side of the ignition module. This sensor protrudes into the block, within approximately 0.050" of the engine crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots cast into it, six of which are evenly spaced 60° apart. A seventh slot is spaced 10° from one of the other slots and serves to generate a "sync pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the crank pulses, the DIS module sends reference signals to the ECM which are used to indicate crankshaft position and engine speed. The ignition module will continue to send these reference pulses to the ECM at a rate of one for each 180° or crankshaft rotation. The ECM will activate the fuel injector based on the recognition of every other reference pulse beginning at a crankshaft position of 120° after top dead center. By comparing the time between pulses, the DIS module can recognize the pulse representing the seventh slot or "sync pulse," which starts the calculation of the ignition coil sequence. The second crank pulse following the "sync pulse" signals the "DIS" module to fire the #2/3 ignition coil and the fifth crank pulse signals the module to fire the #1/4 ignition coil. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Torque Valve Torque Valve Induction Air Sensor 44 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1905 Intake Air Temperature Sensor: Locations Top Rear Of 2.2L Top LH Rear Of Engine, In Air Cleaner Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1906 Intake Air Temperature Sensor: Description and Operation IAT Sensor (Typical) The Intake Air Temperature (IAT) sensor uses a thermistor to control the signal voltage to the ECM. The variable resistor changes its resistance based on temperature. Low intake air temperature produces high resistance, 100,000 ohms at -40°C (-40°F), while a high temperature causes low resistance, 70 ohms at 130°C (266°F). The ECM supplies a 5.0 volt signal to the IAT sensor through a resistor in the ECM and monitors the voltage change. By monitoring the voltage, the ECM calculates the air temperature and uses this data to assist in determining fuel delivery and spark advance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Voltage 3.6 to 5.2 V at 1000 to 2000 ft Note: Note: Apply 10 in. Hg to MAP SENSOR at given altitude and watch voltage. It should drop 1.0 to 1.5 Volts from Voltage Specification given. 3.5 to 5.1 V at 2000 to 3000 ft 3.3 to 5.0 V at 3000 to 4000 ft 3.2 to 4.8 V at 4000 to 5000 ft 3.0 to 4.6 V at 5000 to 6000 ft 2.9 to 4.5 V at 6000 to 7000 ft 2.8 to 4.3 V at 7000 to 8000 ft 2.6 to 4.2 V at 8000 to 9000 ft 2.5 to 4.0 V at 9000 to 10000 ft Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1913 Manifold Pressure/Vacuum Sensor: Locations Engine Component Locations. RH Front Of Dash, LH Side Of Blower Motor Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1914 Manifold Pressure/Vacuum Sensor: Description and Operation Map Sensor The Manifold Absolute Pressure (MAP) sensor measures changes in the intake manifold pressure resulting from engine load and speed changes. The computer sends a 5.0 volt reference signal to the MAP sensor. As pressure changes in the intake manifold occur, the electrical resistance of the MAP sensor also changes. By monitoring the sensor output voltage, the computer can determine the manifold absolute pressure. The higher the MAP voltage output the lower the engine vacuum, which requires more fuel. The lower the MAP voltage output the higher the engine vacuum, which requires less fuel. Under certain conditions, the MAP sensor is also used to measure barometric pressure. This allows the computer to automatically adjust for different altitudes. The computer uses the MAP sensor to control fuel delivery and ignition timing. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1915 Manifold Pressure/Vacuum Sensor: Testing and Inspection Chart C-1D Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1916 Wiring Diagram For MAP Sensor CIRCUIT DESCRIPTION: The Manifold Absolute Pressure (MAP) sensor responds to changes in manifold pressure (vacuum). The ECM sends a five volt reference to the MAP sensor. As manifold pressure changes, the output voltage of the sensor also changes. By monitoring the sensor output voltage, the ECM knows the manifold pressure. A lower pressure output voltage will be approximately 1.0-2.0 volts at idle. Higher pressure output voltage will be approximately 4.0-4.8 volts at Wide Open Throttle (WOT). The MAP sensor is also used, under certain conditions, to measure barometric pressure. This allows the ECM to make engine adjustments for different altitudes. The ECM uses the MAP sensor information to control fuel delivery and ignition timing. TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. 1. When comparing "Scan" readings to a known good vehicle, it is important to compare vehicles that use a MAP sensor having the same color insert or having the same "Hot Stamped" number. 2. Applying 34 kPa (10" Hg.) of vacuum to the MAP sensor should cause the voltage to change. The voltage value should be greater than 1.5 volts. Upon applying vacuum to the sensor, the change in voltage should be instantaneous. A slow voltage change indicates a faulty sensor. 3. Check vacuum hose to sensor for a leak or a restriction. Be sure that no other vacuum devices are connected to the MAP sensor hose. 4. Disconnect sensor from the bracket and twist sensor by hand to check for an intermittent connection. Output changes greater than 0.1 volt indicate a bad connector or connection. If OK, replace the sensor. NOTE: Make sure electrical connector remains securely fastened, and the same diagnostic test equipment is used on all measurements. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensors - Silica Contamination Oxygen Sensor: Technical Service Bulletins Oxygen Sensors - Silica Contamination Model Year: 1981 Bulletin No: 81-I-37 File In Group: 60 Number: 11 Date: Feb. 81 Subject: Silica Contamination of Oxygen Sensors and Gelation of Oil. Models Affected: All Oxygen sensor performance can deteriorate if certain RTV silicone gasket materials are used. Other RTV's when used with certain oils, may cause gelation of the oil. The degree of performance severity depends on the type of RTV and application of the engine involved. Therefore, when repairing engines where this item is involved, it is important to use either cork composition gaskets or RTV silicone gasket material approved for such use. GMS (General Motors Sealant) or equivalent material can be used. GMS is available through GMPD with the following part numbers: 1052366 3 oz. 1052434 10.14 oz. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 1921 Oxygen Sensor: Specifications MINIMUM IDLE SPEED Transmission Gear Idle Speed IAC Counts Open/Closed Loop (2) Auto. D 600 +/-50 (1) CL Man. N 600 +/-50 (1) CL (1) No IAC counts are provided for this vehicle. (2) Let engine idle until proper fuel control status is reached (open/closed loop). TORQUE VALUES EGR valve bolts.................................................................................................................................... .............................................11-18 lb.ft. (15-25 N-m) Oxygen sensor..................................................................................................................................... ..........................................................30 lb.ft. (41 N-m) Throttle Body attaching bolts................................................................................................................ ........................................................18 lb.ft. (25 N-m) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 1922 Oxygen Sensor: Locations Engine Component Locations. Front Of Engine, In Exhaust Manifold Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 1923 LH Front Of 2.2L Front Of Engine, In Exhaust Manifold Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 1924 Oxygen Sensor: Description and Operation Oxygen Sensor The oxygen sensor is located in the exhaust system. The sensor monitors atmospheric air versus exhaust gas oxygen content to produce a voltage output. This voltage ranges from approximately 0.1 volt (high oxygen - lean mixture) to 0.9 volt (low oxygen - rich mixture). By monitoring the oxygen sensor output voltage, the computer can determine the amount of oxygen in the exhaust gas and adjust the air/fuel mixture accordingly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 1925 Oxygen Sensor: Service and Repair The oxygen sensor has a permanently attached wire and connector. This should not be removed, since the removal will affect proper operation of the oxygen sensor. 1. Disconnect electrical connector from oxygen sensor. 2. Using a suitable oxygen sensor wrench, carefully remove the sensor from exhaust manifold or pipe. The oxygen sensor may be difficult to remove when engine temperature is below 120°F. Use CAUTION, since excessive force may damage threads in exhaust manifold or pipe. 3. If a new sensor is being used, install the new sensor into the manifold or pipe. 4. If an old sensor is being reused, coat threads with anti-seize compound, then install the sensor into the manifold or pipe. 5. Torque the oxygen sensor to specifications, then reconnect the electrical connector. See MECHANICAL SPECIFICATIONS for sensor torque specifications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations RH Rear Of Engine Compartment. LH Front Of Dash, Below Brake Booster Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 1929 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch The Power Steering Pressure Switch (PSPS) opens during high pressure power steering situations. When the power steering switch is open, power to the A/C relay is shut off, resulting in air conditioning compressor clutch disengagement. A signal is also sent to the ECM. The ECM uses this signal for idle speed control. A Scan tool should read "off" normally, and "on" with high pressure. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 1934 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor 18 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1935 Throttle Position Sensor: Locations Top Rear Of 2.2L Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 2L/4-134 Engine. 1991 Cavalier Engine Component Locations. Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1936 Throttle Position Sensor: Description and Operation Typical Throttle Position Sensor (TPS) Wiring Throttle Position Sensor PURPOSE The function of the Throttle Position Sensor (TPS) is to sense the current throttle valve position and relay that information to the ECM. Throttle position information allows the ECM to generate the required injector control signals (base pulse). OPERATION If the TPS senses a opening throttle, a voltage signal indicating this condition is sent to the ECM. The ECM then increases the injector pulse width, permitting increased fuel flow. As the throttle valve rotates in response to movement of the accelerator pedal, the throttle shaft transfers this rotation to the TPS. A potentiometer (variable resistor) within the TPS assembly changes its resistance (and voltage drop) in proportion to throttle movement. By applying a reference voltage (5.0 volts) to the TPS input, a varying voltage (reflecting throttle position) is available at the TPS output. For example, approximately 2.5 volts results from a 50% throttle valve opening (depending on TPS calibration). The voltage output from the TPS assembly is routed to the ECM for use in determining throttle position. If the TPS is held in a wide open throttle (WOT) position during engine start, the ECM will interpret this as a clear flood mode. The ECM will then pulse the injectors at a ratio of 20 to 1 in order to clear a flooded condition. The ECM will hold this injector rate as long as the throttle stays wide open, and the engine speed is below 600 rpm. LOCATION The Throttle Position Sensor (TPS), is mounted on the side of the throttle body opposite the throttle lever assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1937 Throttle Position Sensor: Adjustments TPS Adjustment Check The Throttle Position Sensor (TPS) is not adjustable. The normal closed throttle position voltage is below 1.33 volts, and normal wide open throttle position voltage is approximately 5.0 volts. If these limits are not in specification, check for freedom of throttle movement, and accelerator pedal interference from carpets and other obstructions. If the problem is not corrected, replace the TPS. The ECM has the ability to self zero the TPS voltage if it is below approximately 1.33 volts. A TPS voltage that does not fall within 0.33 volts and 1.33 volts should be replaced after checking connections. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1938 Throttle Position Sensor: Service and Repair Model 700 TBI - Exploded View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1939 Throttle Position Sensor REMOVAL: 1. Disconnect the electrical connector. 2. Remove TPS attaching screws. 3. Remove the TPS. CAUTION: The TPS is an electrical component and must not be soaked in any liquid cleaner or solvent, as damage may result. INSTALLATION: 1. With the throttle valve in the closed position, install the TPS on the throttle shaft. Rotate counter clockwise to align mounting holes. 2. Install the TPS attaching screws, finger tighten only. 3. Tighten attaching screws to 2.0 N-m (18 lb. in.) 4. Check TPS voltage: a. Connect a scan tool to the ALDL connector. b. Turn the ignition switch ON. c. Select TPS voltage display on the scan tool, and check voltage. The TPS voltage should be less than 1.25 volts. If the reading is higher than 1.25 volts, check for binding throttle valve or throttle cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations Transmission Position Switch/Sensor: Locations Rear Of 3.1L Rear Of Engine, Top LH Side Of Transaxle Applicable to: 1L/V6-192 Engine. Cavalier w/Automatic Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 1943 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch & Connector The PARK/NEUTRAL switch indicates to the computer when the transmission is in park or neutral. This information is used by the computer for ignition timing, Idle Air Control (IAC), and Transmission Torque Converter Clutch (TCC) operation. DO NOT drive the vehicle with the PARK/NEUTRAL switch disconnected, since idle quality may be affected. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 1944 Transmission Position Switch/Sensor: Testing and Inspection Chart C-1A Wiring Diagram For P/N Switch CIRCUIT DESCRIPTION: The PARK/NEUTRAL switch contacts are closed to ground in park or neutral and open in drive ranges. The ECM supplies ignition voltage through a current limiting resistor to circuit 434, and senses a closed switch when the voltage on circuit 434 drops to less than one volt. The ECM uses the P/N signal as one of the inputs to control idle air and vehicle speed sensor diagnostics. TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 1945 1. Checks for a closed switch to ground in the PARK position. Different makes of "Scan" tools will read PARK/NEUTRAL differently. Refer to operators manual for type of display used for a specific tool. 2. Checks for an open switch in drive range. 3. Be sure the "Scan" tool indicates drive even while wiggling the shifter to test for an intermittent or misadjusted switch in drive. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 1946 Transmission Position Switch/Sensor: Adjustments 1. Place transaxle shift lever in NEUTRAL. 2. Loosen switch attaching screws. 3. Rotate switch on shaft assembly to align service adjustment hole with carrier tang hole. a. Insert 2.34 mm (3/32 inch) maximum diameter gauge pin to a depth of 15.0 mm (5/8 inch). 4. Tighten attaching screws. See SPECIFICATIONS/MECHANICAL for torque values. 5. Remove the gauge pin. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 1947 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Start and Backup Lamp Switch 1. Remove negative battery cable, shift linkage, electrical connector, mounting bolts, and switch assembly. 2. Replacement using old or new switch. a. Place shift shaft in NEUTRAL. b. Align flats of shift shaft with switch. c. Old Switch only - Install mounting bolts-to-case, loosely. Insert gauge pin in service adjustment hole, and rotate switch until pin drops into a depth of 9.0 mm (9/64") and tighten bolts (see SPECIFICATIONS/MECHANICAL for torque values). d. New Switch only - Install mounting bolts and tighten. If bolt holes do not align with mounting boss on transaxle, verify that the shift shaft is in NEUTRAL; DO NOT rotate the switch. The switch is pinned in the NEUTRAL position. NOTE: If the switch has been rotated and the pin is broken, the switch can be adjusted using the old switch procedure and ADJUSTMENT PROCEDURES. 3. See ADJUSTMENT PROCEDURES for PARK/NEUTRAL switch adjustment. 4. After the switch is installed, verify that the engine will start only in PARK (A/T) or NEUTRAL (M/T). If the engine starts in any other position, readjust the switch using old switch procedure and ADJUSTMENT PROCEDURES. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Engine Component Locations. Top RH Rear Of Transaxle Applicable to: 1991 Cavalier w/2.2L/4-134 Rear Of 2.2 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 1951 Top RH Rear Of Transaxle Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 1952 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor The Vehicle Speed Sensor (VSS) is made up of a coil, which is mounted on the transmission, and a tooth rotor which is mounted to the output shaft in the transmission. As each rotor tooth nears the coil, the coil produces an Alternating Current (AC) voltage pulse. As the vehicle speed increases, the number of AC voltage pulses increase. The Digital Ratio Adapter Controller (DRAC) processes input from the VSS sensor and output signals from the speedometer, computer, and cruise control module. The DRAC takes the voltage pulses from the VSS sensor and uses them to open and close four solid state output switches to ground at a rate proportional to vehicle speed. The DRAC is matched to the vehicle based on final drive ratio and tire size. It is important to make sure the correct DRAC module is replaced on the vehicle if replacement is necessary. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations Rear Of Engine RH rear of engine, below intake manifold Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1957 Oil Pressure Switch (For Fuel Pump): Description and Operation Wiring Diagram For Fuel Pump Relay As a back-up system to the fuel pump relay, the fuel pump can also be turned ON by the oil pressure switch. The oil pressure switch is a normally open switch which closes when oil pressure reaches about 28.0 kPa (4.0 psi). If the fuel pump relay fails, the oil pressure switch will power the fuel pump. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1958 Oil Pressure Switch (For Fuel Pump): Testing and Inspection Wiring Diagram For Fuel Pump Relay The oil pressure switch is mounted on the engine. This switch operates as a parallel power supply with the fuel pump relay to supply battery voltage to the fuel pump. Voltage is supplied to the fuel pump after approximately 28 kPa (4 PSI) oil pressure is reached. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1959 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch Located On RH Side Of Engine. Oil sender is located on right hand side of engine, under the DIS coils, under the intake manifold. Remove oil sender by using correct tool on the base of the sending unit. Do not use the body of the oil sender for installation/removal. Use appropriate sealer on threads. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 1964 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor 18 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1965 Throttle Position Sensor: Locations Top Rear Of 2.2L Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 2L/4-134 Engine. 1991 Cavalier Engine Component Locations. Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1966 Throttle Position Sensor: Description and Operation Typical Throttle Position Sensor (TPS) Wiring Throttle Position Sensor PURPOSE The function of the Throttle Position Sensor (TPS) is to sense the current throttle valve position and relay that information to the ECM. Throttle position information allows the ECM to generate the required injector control signals (base pulse). OPERATION If the TPS senses a opening throttle, a voltage signal indicating this condition is sent to the ECM. The ECM then increases the injector pulse width, permitting increased fuel flow. As the throttle valve rotates in response to movement of the accelerator pedal, the throttle shaft transfers this rotation to the TPS. A potentiometer (variable resistor) within the TPS assembly changes its resistance (and voltage drop) in proportion to throttle movement. By applying a reference voltage (5.0 volts) to the TPS input, a varying voltage (reflecting throttle position) is available at the TPS output. For example, approximately 2.5 volts results from a 50% throttle valve opening (depending on TPS calibration). The voltage output from the TPS assembly is routed to the ECM for use in determining throttle position. If the TPS is held in a wide open throttle (WOT) position during engine start, the ECM will interpret this as a clear flood mode. The ECM will then pulse the injectors at a ratio of 20 to 1 in order to clear a flooded condition. The ECM will hold this injector rate as long as the throttle stays wide open, and the engine speed is below 600 rpm. LOCATION The Throttle Position Sensor (TPS), is mounted on the side of the throttle body opposite the throttle lever assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1967 Throttle Position Sensor: Adjustments TPS Adjustment Check The Throttle Position Sensor (TPS) is not adjustable. The normal closed throttle position voltage is below 1.33 volts, and normal wide open throttle position voltage is approximately 5.0 volts. If these limits are not in specification, check for freedom of throttle movement, and accelerator pedal interference from carpets and other obstructions. If the problem is not corrected, replace the TPS. The ECM has the ability to self zero the TPS voltage if it is below approximately 1.33 volts. A TPS voltage that does not fall within 0.33 volts and 1.33 volts should be replaced after checking connections. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1968 Throttle Position Sensor: Service and Repair Model 700 TBI - Exploded View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1969 Throttle Position Sensor REMOVAL: 1. Disconnect the electrical connector. 2. Remove TPS attaching screws. 3. Remove the TPS. CAUTION: The TPS is an electrical component and must not be soaked in any liquid cleaner or solvent, as damage may result. INSTALLATION: 1. With the throttle valve in the closed position, install the TPS on the throttle shaft. Rotate counter clockwise to align mounting holes. 2. Install the TPS attaching screws, finger tighten only. 3. Tighten attaching screws to 2.0 N-m (18 lb. in.) 4. Check TPS voltage: a. Connect a scan tool to the ALDL connector. b. Turn the ignition switch ON. c. Select TPS voltage display on the scan tool, and check voltage. The TPS voltage should be less than 1.25 volts. If the reading is higher than 1.25 volts, check for binding throttle valve or throttle cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 1975 Crankshaft Position Sensor: Mechanical Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1976 Rear Of Engine Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1977 Crankshaft Position Sensor: Description and Operation Typical DIS Crankshaft Sensor This crankshaft sensor is mounted remotely on the bottom side of the ignition module. This sensor protrudes into the block, within approximately 0.050" of the engine crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots cast into it, six of which are evenly spaced 60° apart. A seventh slot is spaced 10° from one of the other slots and serves to generate a "sync pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the crank pulses, the DIS module sends reference signals to the ECM which are used to indicate crankshaft position and engine speed. The ignition module will continue to send these reference pulses to the ECM at a rate of one for each 180° or crankshaft rotation. The ECM will activate the fuel injector based on the recognition of every other reference pulse beginning at a crankshaft position of 120° after top dead center. By comparing the time between pulses, the DIS module can recognize the pulse representing the seventh slot or "sync pulse," which starts the calculation of the ignition coil sequence. The second crank pulse following the "sync pulse" signals the "DIS" module to fire the #2/3 ignition coil and the fifth crank pulse signals the module to fire the #1/4 ignition coil. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking Ignition Switch Lock Cylinder: Customer Interest Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 1987 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 1988 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 1989 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 1990 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 1991 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 1992 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 931943F > May > 93 > Ignition Lock Cylinder Replacement Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Replacement Number: 93-194-3F Section: 3F Date: MAY 1993 Corporate Bulletin No.: 333207 ASE No.: A4 Subject: IGNITION LOCK CYLINDER REPLACEMENT Model and Year: 1991-93 CAVALIER SERVICE UPDATE When drilling out the ignition lock cylinder housing assembly shear bolts, care must be taken to remove the steering column from the car. Both the wiper switch and the turn signal switch must be removed before drilling the bolts out. There is a concern that metal shavings from the drilling of ignition lock cylinder shear bolts may enter the switches and cause the switch to become inoperative. The revised procedure below should be used. REMOVE 1. Steering wheel and covers (see Section 3F). 2. Steering column from vehicle (see Section 3F). 3. Turn signal switch from steering column (see Section 3F). 4. Wash/wipe switch from steering column (see Section 3F). IMPORTANT: Both the turn signal switch and wash/wipe switch have to be removed to prevent any metal shavings from entering the electrical components. 5. Lock cylinder housing assembly as follows: Put key in run position. - Drill off heads of two shear bolts using a 6.5 mm (1/4") drill bit. - Remove lock cylinder housing assembly. - Remove threaded ends of shear bolts from lock cylinder housing assembly with locking type pliers. - Clean all metal shavings from all parts after drilling. INSTALL 1. Lock cylinder housing assembly with two shear bolts. Key in run position. 2. Tighten two shear bolts until bolt head separates from bolt body approximately 11.0 N-m (97 lbs.in.) 3. Wash/wipe switch onto steering column (see Section 3F). 4. Turn signal switch onto steering column (see Section 3F). 5. Steering column into vehicle (see Section 3F). 6. Steering wheel and covers (see Section 3F). NOTE: Because the correct procedure must be followed when replacing ignition lock cylinders, Warranty will not be paid on turn signal or wiper/wash switches for 30 days after an ignition lock cylinder replacement. Use current labor time. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder Key Sticking Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder Key Sticking > Page 2002 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder Key Sticking > Page 2003 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder Key Sticking > Page 2004 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder Key Sticking > Page 2005 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder Key Sticking > Page 2006 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder Key Sticking > Page 2007 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 931943F > May > 93 > Ignition Lock Cylinder Replacement Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Replacement Number: 93-194-3F Section: 3F Date: MAY 1993 Corporate Bulletin No.: 333207 ASE No.: A4 Subject: IGNITION LOCK CYLINDER REPLACEMENT Model and Year: 1991-93 CAVALIER SERVICE UPDATE When drilling out the ignition lock cylinder housing assembly shear bolts, care must be taken to remove the steering column from the car. Both the wiper switch and the turn signal switch must be removed before drilling the bolts out. There is a concern that metal shavings from the drilling of ignition lock cylinder shear bolts may enter the switches and cause the switch to become inoperative. The revised procedure below should be used. REMOVE 1. Steering wheel and covers (see Section 3F). 2. Steering column from vehicle (see Section 3F). 3. Turn signal switch from steering column (see Section 3F). 4. Wash/wipe switch from steering column (see Section 3F). IMPORTANT: Both the turn signal switch and wash/wipe switch have to be removed to prevent any metal shavings from entering the electrical components. 5. Lock cylinder housing assembly as follows: Put key in run position. - Drill off heads of two shear bolts using a 6.5 mm (1/4") drill bit. - Remove lock cylinder housing assembly. - Remove threaded ends of shear bolts from lock cylinder housing assembly with locking type pliers. - Clean all metal shavings from all parts after drilling. INSTALL 1. Lock cylinder housing assembly with two shear bolts. Key in run position. 2. Tighten two shear bolts until bolt head separates from bolt body approximately 11.0 N-m (97 lbs.in.) 3. Wash/wipe switch onto steering column (see Section 3F). 4. Turn signal switch onto steering column (see Section 3F). 5. Steering column into vehicle (see Section 3F). 6. Steering wheel and covers (see Section 3F). NOTE: Because the correct procedure must be followed when replacing ignition lock cylinders, Warranty will not be paid on turn signal or wiper/wash switches for 30 days after an ignition lock cylinder replacement. Use current labor time. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure, Engine Running ......................................................................................................................................................... 62-90 kPa (9-13 P.S.I.) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2020 Fuel Pressure: Testing and Inspection Fuel System Schematic WARNING: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before connecting a fuel pressure test. Refer to Fuel Pressure Release Procedure. CAUTION To reduce the risk of fire and personal injury: 1. It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge. 2. A small amount of fuel may be released when disconnecting the fuel lines. Cover the fuel lines with a shop towel to catch any fuel leaking out. Place the towel in an approved container once the lines are disconnected. 3. DO NOT pinch or restrict nylon fuel lines to avoid severing. If nylon fuel lines become kinked, and cannot be straightened, they must be replaced. 4. Wear safety glasses at all times. FUEL PRESSURE TESTING 1. Loosen fuel filler cap to relieve fuel tank pressure. (DO NOT tighten at this time.) 2. Raise the vehicle to disconnect the fuel pump electrical connector, then lower the vehicle. 3. Start and run the engine until the residual fuel is consumed. Engage starter for three seconds to assure fuel pressure relief. 4. Disconnect the negative battery cable, and locate the fuel feed pressure line. 5. Connect fuel pressure gage, J-29658-B, in between the fuel feed line and the TBI unit. Use the appropriate adapters. 6. Raise the vehicle to connect the fuel pump electrical connector, then lower the vehicle. 7. Connect the negative battery terminal. 8. Perform fuel pressure checks. 9. Relieve the fuel system pressure. See steps 2 and 3. 10. Disconnect the negative battery terminal and remove fuel pressure gauge. 11. Tighten fuel filler cap and connect the negative battery terminal. 12. Cycle the ignition switch twice, waiting ten seconds between cycles. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Vin R, U, G, Minimum Idle Speed Vin R, U, G, Minimum Idle Speed Idle Speed Note: Let engine idle until proper fuel control status is closed loop. Manual Transmission Neutral 600 +/-50 rpm Automatic Transmission Drive 600 +/-50 rpm Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Idle Speed Idle Speed: Adjustments Idle Speed The throttle plate stop screw, or idle speed, is adjusted at the factory and covered with a plug to discourage unnecessary adjustment. But, if access to the throttle stop screw is necessary, the following procedure eliminates the removal of the Throttle Body unit from the intake manifold. If there is a complaint of high idle speed, vacuum leaks should be considered the most likely cause. The Electronic Control Module (ECM) controls the Idle Air Control (IAC) valve, and it is less likely that a stalling complaint would be due to incorrect idle speed. If either occurs see DIAGNOSIS BY SYMPTOM. If the Minimum Air Rate is suspected, be sure the Idle Air Control (IAC) valve is not "lost" (not actually at the location indicated by current IAC "counts"). The IAC valve could be "lost" if ECM power has been interrupted with the ignition "ON," or the IAC valve has been disconnected with the engine running since the last reset. CAUTION: To prevent engines from running at high speeds, be sure that the ignition is OFF and the vehicle is in PARK or NEUTRAL before connecting Idle Air Control (IAC) assembly, or installing/removing idle air passage plugs. Failure to do this may result in vehicle movement, which can result in personal and/or property damage. Stop Screw Plug Removal The Idle Speed may be checked using the following procedure: 1. Block drive wheels and apply parking brake. 2. Remove the air cleaner housing, and plug the Thermac vacuum port (if applicable). 3. Remove the idle stop screw plug with an awl. 4. Start the engine and allow it to reach operating temperature. 5. Connect a tachometer to the engine. 6. With Idle Air Control (IAC) valve connected, jump terminals A and B of the ALDL connector to ground the diagnostic terminal. See ON-BOARD DIAGNOSTIC CHECK for ALDL diagram. 7. Turn the ignition ON, but do not start the engine. Wait at least 45 seconds to allow the IAC pintle time to bottom in its seat. This closes the air passage in the TBI unit. 8. With the ignition ON, engine not running and diagnostic lead grounded, disconnect the IAC valve electrical connector. 9. Remove the ground from the diagnostic connector, and start the engine. Allow the engine speed to stabilize. 10. Adjust the idle stop screw. See MECHANICAL SPECIFICATIONS for idle speed specifications. 11. Turn OFF the ignition and reconnect the IAC electrical connector. 12. Reset the IAC valve by starting the engine and allowing it to run at 2000 rpm for ten seconds. Then turn OFF the ignition switch. 13. Cover the idle stop screw with silicone or similar sealant. 14. Remove the test instruments and reinstall the air cleaner housing. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Idle Speed > Page 2026 Idle Speed: Adjustments Minimum Air Rate - Fuel Injection Only NOTE: The minimum idle air rate is set at the factory with a stop screw and is not normally readjusted unless repairs or replacement of the throttle body assembly has occurred. Engine idle speed is computer controlled through the IAC valve and is not adjustable. If there is a complaint of high idle speed, vacuum leaks should be considered the most likely cause. The Electronic Control Module (ECM) controls the Idle Air Control (IAC) valve, and it is less likely that a stalling complaint would be due to incorrect minimum idle speed. If either occurs, refer to Diagnosis by Symptom. If the Minimum Air Rate is suspected, be sure the Idle Air Control (IAC) valve is not "lost" (not actually at the location indicated by current IAC "counts"). The IAC valve could be "lost" if ECM power has been interrupted with the ignition "ON," or the IAC valve has been disconnected with the engine running since the last reset. CAUTION: To prevent engines from running at high speeds, be sure that the ignition is OFF and the vehicle is in PARK or NEUTRAL before connecting Idle Air Control (IAC) assembly, or installing/removing idle air passage plugs. Failure to do this may result in vehicle movement, which can result in personal and/or property damage. MINIMUM IDLE AIR RATE CHECK 1. START engine and bring it to normal operating temperatures 185-212 degrees Fahrenheit (85-100 degrees Celsius). Turn engine OFF. 2. Remove air cleaner assembly. Remove hoses and plug any possible air sources on tube manifold assembly. 3. Disconnect throttle cable. 4. Ground diagnostic "test" terminal in ALDL connector. (jumper A to B) 5. Turn ON ignition, DO NOT START engine. Wait at least 10 seconds (this will allow the IAC pintle to extend and seat in the throttle body). 6. With ignition ON, engine stopped, test terminal still grounded, disconnect IAC valve electrical connector. (This disables the IAC valve in the seated position). Remove the ground from the diagnostic terminal. 7. Connect a scan tool to the ALDL connector and place in open mode. If a tool is not available connect a tachometer to the engine. 8. START engine. With transmission in NEUTRAL, allow engine rpm to stabilize. It may be necessary to depress the accelerator in order to start the engine. 9. Idle speed should be 550 to 650 RPM. Adjust idle stop screw if necessary. To remove the soft plug, puncture with an awl and pry out. Stop Screw Plug Removal 10. If the minimum idle air rate is within 550 to 650 RPM, no further check is required. 11. Turn ignition OFF and reconnect IAC valve electrical connector. 12. Disconnect the SCAN tool or tachometer. 13. The IAC valve will be reset by the computer when the vehicle speed exceeds 43 MPH while the engine speed is above 2000 RPM or when the diagnostic test connector is grounded when the engine RPM is above 2000 RPM. 14. Install air cleaner, adapter, gasket and vacuum hoses. NOTE: The minimum idle air rate is set at the factory with a stop screw, which is covered with a tamper plug. This setting allows enough air flow by the Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Idle Speed > Page 2027 throttle valves to cause the IAC valve pintle to be positioned a calibrated number of steps (counts), from the seat, during "controlled" idle operation. If the IAC valve is disconnected and reconnected with the engine running, the idle speed may be wrong. In this case, the IAC valve can be reset by doing the following: The IAC valve will be reset by the computer when the vehicle speed exceeds 43 MPH while the engine speed is above 2000 RPM or when the diagnostic test connector is grounded when the engine RPM is above 2000 RPM. Engine idle speed is computer controlled through the IAC valve, by driving the IAC pintle in and out. Engine idle speed is a funtion of total air flow into the engine based on: IAC valve position, throttle valve opening (idle stop screw), calibrated leakage through the accessories, PCV flow. "Controlled" idle speed is programed into the ECM, which determines the correct IAC valve pintle position to maintain the desired idle speed. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 2037 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 2043 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair WARNING: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing fuel system components. After relieving system pressure, a small amount of fuel may be released when servicing fuel lines or connections. In order to reduce the chance of personal injury, cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when disconnect is completed. When servicing the fuel system use the following precautions: a. Put a "CAUTION FLAMMABLE" sign in the workshop. b. Be sure shop is supplied with an adequate fire extinguisher. c. Be sure to disconnect battery ground cable before any service work is done. d. Use a suitable container to catch any fuel that may leak from the system during service. e. Always relieve fuel system pressure before disconnecting any lines. f. If the key must be turned ON while servicing the fuel system, always disconnect or disable the ignition, to insure no sparks occur near fuel vapors. g. NEVER turn the ignition on while servicing the fuel system unless the electric fuel pump is disabled. PROCEDURE: 1. Loosen fuel filler cap to relieve tank vapor pressure. 2. Raise the vehicle and disconnect fuel pump electrical connector at fuel tank. 3. Lower vehicle. 4. START engine and RUN until fuel supply remaining in fuel pipes is consumed. Engage starter for 3 seconds to relieve the remaining fuel pressure. 5. Perform required tests or repairs. 6. Raise vehicle and reconnect fuel pump electrical connector at fuel tank. 7. START vehicle for 10 seconds. Shut vehicle OFF and check for leaks. 8. Retighten the fuel tank cap. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Ignition Firing Order Firing Order: Specifications Ignition Firing Order Firing Order ......................................................................................................................................... ....................................................................... 1-3-4-2 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations > Number 1 Cylinder Location Number One Cylinder: Locations Number 1 Cylinder Location NUMBER ONE CYLINDER LOCATION Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Technical Service Bulletins > Customer Interest: > 93356D > Oct > 92 > Engine - Miss, Hesitation, or Roughness Spark Plug Wire: Customer Interest Engine - Miss, Hesitation, or Roughness Number: 93-35-6D Section: 6D Date: OCT. 1992 Corporate Bulletin No.: 716404R ASE No.: A1, A8 Subject: ENGINE MISS HESITATION OR ROUGHNESS DUE TO PIERCED SECONDARY IGNITION COMPONENTS Model and Year: 1980-93 ALL PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 87-121, DATED MAY 1987. THE 1989-93 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 87-121 SHOULD BE DISCARDED. During the diagnosis procedure for an engine miss, hesitation or roughness, a spark plug or spark plug wire condition may be suspected. Several types of commercial or homemade diagnostic equipment required the secondary ignition boots or wire to be pierced. This is normally done to check for spark plug firing or to perform a cylinder balance test. Similarly the use of pliers or other such tools to disengage a spark plug boot may pierce or damage the boot or wire. Secondary ignition components should not be pierced for any reason. Piercing a spark plug wire and/or distributor boot may create a condition that will not be immediately apparent. Over time, the hole in the pierced boot may allow a ground path to develop creating a plug misfire condition. Heavily moisture laden air in the vicinity of the pierced boot may accelerate this effect. Piercing a secondary ignition wire creates a gap in the wire's conductive core. This gap is a point of high resistance. The current flow in the wire will increase to compensate for the higher wire resistance. Over time, the wire may fail creating a plug misfire condition. The time required for the condition to appear depends upon the extent of damage to the conductive core. To help prevent future condition that are spark plug wire related, do not pierce or otherwise damage any secondary ignition component. Only use diagnostic equipment containing an inductive pick-up to check for spark plug firing or to perform cylinder balance tests. When disengaging a spark plug boot from the spark plug, twist the flanged boot 1/2 turn then pull on the boot only to remove the wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 93356D > Oct > 92 > Engine - Miss, Hesitation, or Roughness Spark Plug Wire: All Technical Service Bulletins Engine - Miss, Hesitation, or Roughness Number: 93-35-6D Section: 6D Date: OCT. 1992 Corporate Bulletin No.: 716404R ASE No.: A1, A8 Subject: ENGINE MISS HESITATION OR ROUGHNESS DUE TO PIERCED SECONDARY IGNITION COMPONENTS Model and Year: 1980-93 ALL PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 87-121, DATED MAY 1987. THE 1989-93 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 87-121 SHOULD BE DISCARDED. During the diagnosis procedure for an engine miss, hesitation or roughness, a spark plug or spark plug wire condition may be suspected. Several types of commercial or homemade diagnostic equipment required the secondary ignition boots or wire to be pierced. This is normally done to check for spark plug firing or to perform a cylinder balance test. Similarly the use of pliers or other such tools to disengage a spark plug boot may pierce or damage the boot or wire. Secondary ignition components should not be pierced for any reason. Piercing a spark plug wire and/or distributor boot may create a condition that will not be immediately apparent. Over time, the hole in the pierced boot may allow a ground path to develop creating a plug misfire condition. Heavily moisture laden air in the vicinity of the pierced boot may accelerate this effect. Piercing a secondary ignition wire creates a gap in the wire's conductive core. This gap is a point of high resistance. The current flow in the wire will increase to compensate for the higher wire resistance. Over time, the wire may fail creating a plug misfire condition. The time required for the condition to appear depends upon the extent of damage to the conductive core. To help prevent future condition that are spark plug wire related, do not pierce or otherwise damage any secondary ignition component. Only use diagnostic equipment containing an inductive pick-up to check for spark plug firing or to perform cylinder balance tests. When disengaging a spark plug boot from the spark plug, twist the flanged boot 1/2 turn then pull on the boot only to remove the wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug Wire: > 912633 > Mar > 91 > Dash - Squeak/Squawk Noise on Turns Steering Gear Mount: All Technical Service Bulletins Dash - Squeak/Squawk Noise on Turns Number: 91-263-3 Section: 3 Date: MARCH 1991 Corp. Bulletin No.: 133201 Subject: NOISE FROM FRONT OF DASH WHEN TURNING Model and Year: 1990-91 CAVALIER, CORSICA, BERETTA Condition: Customers may comment about a squawk/creak noise from the front of dash when turning. They may also comment about a slight feeling of vague on-center steering and slow returnability. Cause: After a extended heat soak the grommet material starts to take a compression set. This set will lead to a rub condition between the gear and the grommet during steering. Correction: As part of trouble shooting, refer to Dealer Service Bulletin No. 90-409-3 for VIN breakpoints regarding the steering gear to front of dash clamp retaining nuts and inspect them. If the retaining nuts are not loose, it may be necessary to replace only the steering gear mounting grommets. If the retaining nuts are loose, it will be necessary to replace both the retaining nuts and steering gear mounting grommets. STEERING GEAR MOUNTING REPLACEMENT GROMMETS SUSPENSION RIGHT LEFT LEVEL PART NUMBER PART NUMBER FE1 26001492 7849985 FE2 26001492 26000626 FE3 26001492 26000626 FE7 (GTZ only) 26001492 26000626 Parts are currently available from GMSPO. Vehicles with possible grommet noise conditions were produced between breakpoints listed below: From the following serial From the start of 1991 number to the end of 1990 production to the production: following serial number: "J" (Lordstown) L7166829 "J" (Lordstown) M7164949 "J" (Janesville) U244293 "J" (Janesville) MJ174173 "L" (Wilmington) LY211048 "L" (Wilmington) MY148179 "L" (Linden) LE207500 "L" (Linden) ME138400 Labor Operation Number: T1716 Labor Time: 0.9 Hour Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Technical Service Bulletins > Page 2080 Spark Plug Wire: Specifications Ignition Wire Resistance: 1-15 in. ................................................................................................................................................. .......................................... 3000/10,000 ohms 15-25 in. ..................................................................... .................................................................................................................... 4000/15,000 ohms 25-35 in. ......................................................................................................................................................... ................................ 6000/20,000 ohms OVER 35 in. ......................................................................... .......................................................................................................... 8000/25,000 ohms Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Locations > Spark Plug Wire Routing Ignition Wire Location Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug Wire <--> [Ignition Cable] > Component Information > Locations > Spark Plug Wire Routing > Page 2083 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plug - Torque Specification Update Spark Plug: Technical Service Bulletins Spark Plug - Torque Specification Update Number: 91-79-6A Section: 6A Date: October 1990 Corporate Bulletin No.: Subject: SPARK PLUG TORQUE SPECIFICATIONS Model and Year: 1990 CELEBRITY 1990-91 BERETTA, CORSICA CAMARO, CAVALIER AND LUMINA, 1990-91 U VAN (APV) TO: ALL CHEVROLET DEALERS When installing spark plugs in the 3.1L engine use the following revised specification in the Service Manuals listed below: Cast Iron or Aluminum Heads, 15 N-m (11 lbs.ft.) 1991 Lumina Pages 6D4 - 4, 5, 7 Cavalier Pages 6A3 - 19 Camaro Pages 6A2 - 31 Pages 6D4 - 7, 9 Corsica/Beretta Pages 6D4 - 3, 6 Pages 6A5 - 24 Lumina (APV) Pages 6A4 - 20, 46 and 6D4 - 6 1990 Celebrity Pages 6D4 - 3, 5 Lumina Pages 6D4 - 4, 5, 6 Cavalier Pages 6A3 - 19 Pages 6D4 - 3 Camaro Pages 6A2 - 30 Pages 6D4 - 7, 8 Corsica/Beretta Pages 6A5 - 20 Pages 6D4 - 2 Lumina (APV) Pages 6A4 - 17, 41 and 6D4 - 6 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plug - Torque Specification Update > Page 2088 Spark Plug: Technical Service Bulletins Spark Plugs - Revised Number: 93-03-6D Section: 6D Date: AUGUST 1992 Corporate Bulletin No.: 166001R ASE No.: Al, A6, A8 Subject: NEW DESIGN SPARK PLUGS Model and Yew: 1991-93 ALL PASSENGER CARS AND TRUCKS WITH GASOLINE ENGINES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO., 91-234A-OB, DATED JULY 1992. THE 1992 AND 1993 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 91-234A-OB SHOULD BE DISCARDED. In 1991 GM introduced a new design spark plug for use in all trucks equipped with gas engines. These new design spark plugs have a ceramic insulator which is approximately 1/8 inch longer than the insulator used in previous model years. The longer length spark plugs, which conform to S.A.E. and I.S.O. Engineering guidelines, magnify the problem of cracked insulators because currently, most spark plug sockets are not of sufficient length to properly engage the shell hex. If the spark plug shell hex is not fully engaged in the spark plug socket wrench, the socket may cock at an angle and cause insulator cracking and/or breakage during plug installation or removal. When servicing these new design spark plugs, make sure that the spark plug socket being used is deep enough to accommodate the longer length insulator. The spark plug socket wrench should conform to the proposed S.A.E. and I.S.O. world standards for spark plug socket wrenches. Spark plug socket wrenches that conform to these standards are designed to accept the lengthened spark plugs and allow full engagement of the hex nut on the shell of the spark plug. Use of a spark plug socket which is NOT deep enough may result in the ceramic insulator becoming cracked above the spark plug shell. Note: SOME CRACKS IN THE INSULATOR M" NOT BE VISIBLE. SUCH CRACKS MAY LATER CAUSE A SPARK PLUG TO MISFIRE. SPARK PLUG MISFIRES ARE OFTEN MISDIAGNOSED AS A SLIPPING TRANSMISSION, DEFECTIVE TORQUE CONVERTER CLUTCH, ENGINE IMBALANCE, OR MALFUNCTIONING FUEL SYSTEM. To prevent insulator damage, it is recommended that the proper spark plug socket wrench be used when removing or replacing spark plugs. One such spark plug socket is the Kent-Moore J-39358 spark plug socket. The tool is available from Kent-Moore. For ordering information call 1 -800-345-2233 or write: Kent-Moore SPX Corporation 39784 Little Mack Roseville, MI 48066-2298 Fax: 313-774-9870 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2089 Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ................................................... 0.90 mm (035 in.) Spark Plug Torque ............................................. ......................................................................................................................... 10 - 20 Nm (7 - 15 ft lb) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The lowest reading cylinder should not be less than 70% of the highest and no cylinder reading should be less than 689 kPa (100 psi). Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications ROCKER ARM TORQUE Fig. 7 Rocker Arm Cover, Rocker Arms & Pushrod Replacement ^ Rocker Arms are not adjustable on this engine, tighten Rocker Arm Nuts to 30 Nm (22 lbs. ft.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2096 Valve Clearance: Adjustments The Rocker Arms are not adjustable on this engine refer to Rocker Arm / Service and Repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2097 Valve Clearance: Service and Repair The Rocker Arms are not adjustable on this engine refer to Rocker Arm / Service and Repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Torque Valve Torque Valve Induction Air Sensor 44 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2102 Intake Air Temperature Sensor: Locations Top Rear Of 2.2L Top LH Rear Of Engine, In Air Cleaner Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2103 Intake Air Temperature Sensor: Description and Operation IAT Sensor (Typical) The Intake Air Temperature (IAT) sensor uses a thermistor to control the signal voltage to the ECM. The variable resistor changes its resistance based on temperature. Low intake air temperature produces high resistance, 100,000 ohms at -40°C (-40°F), while a high temperature causes low resistance, 70 ohms at 130°C (266°F). The ECM supplies a 5.0 volt signal to the IAT sensor through a resistor in the ECM and monitors the voltage change. By monitoring the voltage, the ECM calculates the air temperature and uses this data to assist in determining fuel delivery and spark advance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation Coolant Temperature Sensor (CTS) The engine coolant temperature sensor is a thermistor that is located in the engine coolant flow. When the coolant temperature is low, the sensor produces a high resistance. When the coolant temperature is high, the sensor produces a low resistance. The computer sends a 5.0 volt signal to the coolant temperature sensor through a resistor in the ECM and measures the voltage. The voltage will be high or low depending on coolant temperature. By varying the voltage, the computer will sense engine coolant temperature. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2111 Crankshaft Position Sensor: Mechanical Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2112 Rear Of Engine Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2113 Crankshaft Position Sensor: Description and Operation Typical DIS Crankshaft Sensor This crankshaft sensor is mounted remotely on the bottom side of the ignition module. This sensor protrudes into the block, within approximately 0.050" of the engine crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots cast into it, six of which are evenly spaced 60° apart. A seventh slot is spaced 10° from one of the other slots and serves to generate a "sync pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the crank pulses, the DIS module sends reference signals to the ECM which are used to indicate crankshaft position and engine speed. The ignition module will continue to send these reference pulses to the ECM at a rate of one for each 180° or crankshaft rotation. The ECM will activate the fuel injector based on the recognition of every other reference pulse beginning at a crankshaft position of 120° after top dead center. By comparing the time between pulses, the DIS module can recognize the pulse representing the seventh slot or "sync pulse," which starts the calculation of the ignition coil sequence. The second crank pulse following the "sync pulse" signals the "DIS" module to fire the #2/3 ignition coil and the fifth crank pulse signals the module to fire the #1/4 ignition coil. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2118 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2119 Engine Control Module: Technical Service Bulletins ECM/PCM - Damage Prevention Number: 91-318-6E Section: 6E Date: MAY 1991 Corp. Bulletin No.: 176502R Subject: DAMAGE TO ECM/PCM CIRCUIT BOARD WHEN INSTALLING A MEM-CAL Model and Year: 1986-91 ALL PASSENGER CARS AND TRUCKS CONDITION: When installing a service replacement ECM/PCM, the use of incorrect MEMCAL installation procedures may cause the ECM/PCM to fail before it can be installed in the vehicle. This condition may appear as if the ECM/PCM were defective when it was shipped to the dealership, when in fact it was damaged while being installed. In addition this condition may also occur when installing an "updated" service MEM-CAL into the vehicles original equipment ECM/PCM. CAUSE: Excessive vertical force may be applied to the MEM-CAL resulting in flexing of the circuit board and damage to the connections between the circuit board and attached components. Excessive verticle force may be generated in two ways. 1. Incorrect MEM-CAL installation procedure. 2. Interference between MEM-CAL and cover. CORRECTION: Use the following procedure. Service Procedure: Important: This procedure supersedes any instructions regarding MEM-CAL installation dated prior to September 1990. 1. Inspect the MEM-CAL to determine if a cork spacer is glued to the top side of the MEM-CAL assembly. If so, remove it prior to installation. 2. Align small notches with matching notches in the ECM/PCM MEM-CAL socket. 3. VERY GENTLY press down on the ends of the MEM-CAL until the locking levers are rotated toward the sides of the MEM-CAL. Notice: To avoid ECM/PCM damage, do not press on the ends of the MEM-CAL until the levers snap into place. Do not use any vertical force beyond the minimum required to engage the MEM-CAL into its socket. 4. While continuing light pressure on the ends of MEM-CAL, use your index fingers to press the locking levers inward until they are snapped into place. Listen for click. 5. Install MEM-CAL cover and install ECM/PCM in vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2120 Engine Control Module: Technical Service Bulletins ECM/PCM - Damaged and/or Misdiagnosed Number: 91-384-6E Section: 6E Date: AUGUST 1991 Corporate Bulletin No.: 176503 Subject: DAMAGED ECM/PCM AND/OR MIS-DIAGNOSED ECM/PCM SYMPTOMS DUE TO INCORRECT "TAP-TESTING" PROCEDURES Model and Year: 1982-91 ALL PASSENGER CARS AND TRUCKS CONDITION: Because of the intermittent nature of some Electronic Control Module (ECM) or Powertrain Control Modules (PCM) symptoms, some service technicians have been subjecting the ECM/PCM to vibration and/or shock testing. Commonly known as tap-testing, this procedure involves tapping on the ECM/PCM case, while the engine is running. It is generally accepted that if the engine or ECM/PCM falters due to the tapping, an intermittent internal ECM/PCM defect may be indicated. However, this may not always be true. If too much force is applied to the ECM/PCM during the test the following symptoms may result: ^ Immediate ECM/PCM failure. ^ ECM/PCM suffers damage which may cause a failure at a later date. ^ ECM/PCM Reset (or Glitch), creating a momentary stall, miss Service Engine Soon (SES) light and/or loss of serial data. CAUSE: The ECM/PCM should be tapped using only the fingertips of one hand. Use of the palm, fist, or any type of tool subjects the ECM/PCM to forces that can cause both the circuit board and the outer aluminum case to flex and distort beyond design limits. The Integrated Circuits (IC) used in today's ECM/PCMs are mounted to the circuit board using a mounting process referred to as "surface technology." There are no circuit board holes for IC leads to go through. The IC leads set on pads, (28 pads or 52 pads depending on the IC) and solder is flowed around the leads to make the electrical connection to the circuit board. ^ Any flexing of the circuit board, beyond design limits, places the IC solder connections at risk of damage. Such damage may be apparent immediately, or it may appear at a future date. Circuit board deflection can occur as a result of striking the ECM/PCM, using ONLY THE PALM OF THE HAND. ^ If struck on the bottom side (the side opposite the service label), the ECM/PCM's aluminum outer case may deflect inward far enough to contact the electrical leads attached to the circuit board. Once in contact with the case the ECM/PCM electrical components will be shorted directly to ground. Although such shorting certainly has the potential to damage the ECM/PCM, it may not be permanent damage, depending on which circuit is involved. However, even if permanent damage is avoided, a short on any of the circuits will cause a disruption of normal ECM/PCM operation for the instant that the short occurs. This disruption may cause the ECM/PCM to reset (see "reset" above), creating the false impression that it is vibration sensitive or faulty. Reset is the ECM/PCM's normal way of coping with large voltage spikes. An ECM/PCM reset does not indicate that the ECM/PCM is defective or faulty, only that it is being subjected to abnormal conditions. CORRECTION: 1. TAP THE ECM/PCM ONLY ON THE TOP SIDE (The top side is where the service label is located.) ^ This will minimize the chance of deflecting the ECM/PCM case into the electrical leads on the circuit board. The clearance between the case and the circuit board is closest on the bottom side of the ECM/PCM. 2. TAP THE ECM/PCM USING ONLY THE FINGERTIPS - NO TOOLS. ^ To avoid excessive case deflection, avoid tapping in the center of the case. Tapping close to the edge of the ECM/PCM, especially in the corners, is best. ^ While using greater force may seem more effective, the test itself may cause the ECM/PCM to fail. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications Engine Control Module: Specifications Computer Terminal Voltage Specifications ECM Connector Terminal End View WIRE COLOR ABBREVIATION BLACK BLK Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 2123 BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 2124 Engine Control Module: Specifications ECM Terminal Identification & Voltage Specifications ECM Connector Terminal End View WIRE COLOR ABBREVIATION BLACK BLK Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 2125 BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 2126 ECM Connector Terminal End View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Specifications > Page 2127 ECM Located In Passenger Compartment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Specifications > Page 2128 ECM Connector Terminal End View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control Module (ECM) Engine Control Module: Description and Operation Electronic Control Module (ECM) Closed Loop Operation ECM And PROM Access Cover The Electronic Control Module (ECM) is located in the passenger compartment and is the control center of the Computer Command Control (C3) system. The ECM constantly receives information from various sensors. The computer performs the diagnostic functions of the system. The computer can recognize operational problems and alert the driver through the "SERVICE ENGINE SOON" light. The computer stores a trouble code which identifies the problem area to diagnose and repair. The computer is designed to process the various input information, and send the necessary electrical response to control fuel delivery, spark control, and other emission control systems. The computer used in these vehicles is a type called GMP4. The computer can control these devices through the use of Quad Driver Modules (QDM). When the ECM is commanding a device or a component "ON," the voltage potential of the output is "LOW" or near zero volts. When the ECM is commanding a device or component "OFF," the voltage potential of the circuit will be "HIGH," or near 12 volts. The primary function of the QDM is to supply the ground for the component being controlled. The input information has an interrelation between sensor output. If one of the input devices failed, such as the oxygen sensor, this could affect more than one of the systems controlled by the computer. The computer has a learning ability which allows it to make corrections for minor variations in the fuel system to improve driveability. If the battery is disconnected to clear trouble codes or for repair, the learning process has to begin all over again, and a change may be noticed in the driving performance of the vehicle. To reset the vehicles learning ability, make sure the engine is at operating temperature and operate the vehicle at part throttle, moderate acceleration, and idle conditions, until normal performance returns. The ECM used in these vehicles uses an ECM with two serviceable parts. A controller called a ECM, without a PROM, and a PROM with specific programming information. NOTE: When a production ECM is replaced with a service ECM, it is important to transfer the broadcast code and production number from the original ECM to the service ECM. This allows for positive identification of ECM parts throughout the service life of the vehicle. DO NOT affix the information to the ECM cover. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control Module (ECM) > Page 2131 Engine Control Module: Description and Operation Throttle Body Fuel Injection Control Modules Powertrain Control Module (PCM) The Electronic Control Module (ECM) is located in the passenger compartment and is the control center of the Computer Command Control (C3) system. The ECM constantly receives information from various sensors. The computer performs the diagnostic functions of the system. The computer can recognize operational problems and alert the driver through the "SERVICE ENGINE SOON" light. The computer stores a trouble code which identifies the problem area to diagnose and repair. The computer is designed to process the various input information, and send the necessary electrical response to control fuel delivery, spark control, and other emission control systems. The computer can control these devices through the use of Quad Driver Modules (QDM). When the ECM is commanding a device or a component "ON," the voltage potential of the output is "LOW" or near zero volts. When the ECM is commanding a device or component "OFF," the voltage potential of the circuit will be "HIGH," or near 12 volts. The primary function of the QDM is to supply the ground for the component being controlled. The input information has an interrelation between sensor output. If one of the input devices failed, such as the oxygen sensor, this could affect more than one of the systems controlled by the computer. The computer has a learning ability which allows it to make corrections for minor variations in the fuel system to improve driveability. If the battery is disconnected to clear trouble codes or for repair, the learning process has to begin all over again, and a change may be noticed in the driving performance of the vehicle. To reset the vehicles learning ability, make sure the engine is at operating temperature and operate the vehicle at part throttle, moderate acceleration, and idle conditions, until normal performance returns. A vehicle equipped with a 4-cylinder engine has an ECM referred to as GMP4 with two parts for service. A controller which is the ECM itself, without a MEM-CAL, and a memory calibration unit called a MEM-CAL (PROM). Vehicles with a V-6 or V-8 cylinder engine have an ECM referred to as GMCM with three serviceable parts. A controller called a ECM, without a PROM, a PROM with specific programming information, and a CAL-PAK with specific engine specifications. NOTE: When a production ECM is replaced with a service ECM, it is important to transfer the broadcast code and production number from the original ECM to the service ECM. This allows for positive identification of ECM parts throughout the service life of the vehicle. DO NOT affix the information to the ECM cover. C3 Self Diagnostics ALDL Connector Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control Module (ECM) > Page 2132 Use a "Scan" tool or ground the diagnostic test terminal with the engine not running and the ignition switch in the "ON" position in order to retrieve codes. The "SERVICE ENGINE SOON" light will flash a Code 12 three times and then flash each code stored in memory three times, if the "Scan" tool is not used. Once all Codes are retrieved, a Code 12 will follow. New codes cannot be stored in the ECM once the diagnostics mode is activated. See DIAGNOSTIC CIRCUIT CHECK for a complete system check. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics Some control module's may have problems due to cracked solder joints on the circuit board. These internal control module problems can cause the following symptoms: ^ Failure to start or vehicle is stalling. ^ The "CHECK ENGINE" "SERVICE ENGINE SOON" or "MALFUNCTION INDICATOR" light will flash or light up, but no trouble codes will be present. ^ Vehicle instrument panel displays may be inoperative. ^ The control module may or may not communicate with the scanner. ^ Other intermittent driveability problems. Incorrect PROM or MEMCAL removal and replacement can create solder joint problems or aggravate an existing condition. See PROM or MEMCAL INSTALLATION for proper procedures. If a solder joint problem results in a "hard" failure, normal test procedures will usually pinpoint a faulty control module. Many symptoms caused by poor solder joints in the control module result in intermittent problems, but they may be hard to duplicate during troubleshooting. Control module's with solder joint problems are sensitive to heat and vibration. You can check for these internal control module problems in either, or both, of the following ways: ^ Remove the control module from its mounting bracket and extend it on the harness so that you can expose it to the vehicle heater ducts. Alternatively, use flexible ducting to route air from the heater to the control module location. Then run the engine and operate the heater at the "MAX HEAT" position. This exposes the control module to approximately 140°F. ^ With the engine running, tap on the control module several times with your hand or finger tips to simulate vehicle vibration. If the engine stumbles or stalls, the "CHECK ENGINE" "SERVICE ENGINE SOON" or "MALFUNCTION INDICATOR" light flashes, or any of the previous symptoms occur, the control module may have bad solder joints on the circuit board. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) Replacement Engine Control Module: Service and Repair Engine Control Module (ECM) Replacement ECM Located In Passenger Compartment. ECM And PROM Access Cover Prom Removal And Tool Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) Replacement > Page 2137 When replacing a production ECM with a service ECM, transfer the broadcast code and production number from the production unit to the service unit. Also, during replacement, the PROM must be removed from the ECM being replaced and transferred to the new unit. Some ECM's are equipped with another chip called a Cal-Pak. If the ECM if equipped with a Cal-Pak chip, it will be located next to the PROM and must be transferred along with the PROM. 1. Disconnect battery ground cable. 2. Then disconnect two computer electrical connectors. 3. Remove computer mounting hardware. 4. Remove computer from passenger compartment. 5. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) Replacement > Page 2138 Engine Control Module: Service and Repair Throttle Body Fuel Injection ECM Replacement When replacing a production ECM with a service ECM, transfer the broadcast code and production number from the production unit to the service unit. Also, during replacement, the PROM, CALPACK and if equipped, the MEMCAL must be removed from the ECM being replaced and transferred to the new unit. Refer to PROM, CALPAK, and MEMCAL for procedures. 1. Disconnect battery ground cable. 2. Then disconnect computer electrical connectors. 3. Remove computer mounting hardware. 4. Remove computer from passenger compartment. 5. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations Idle Speed/Throttle Actuator - Electronic: Locations Top Of 2. Top Of Engine, On Throttle Body Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 2142 Idle Speed/Throttle Actuator - Electronic: Description and Operation Idle Air Control Operation PURPOSE The purpose of the idle air control (IAC) valve is to provide a way for the engine control module (ECM) to control engine idle speed. OPERATION Engine idle speeds are controlled by the ECM through the Idle Air Control (IAC) valve mounted on the throttle body. The ECM sends voltage pulses to the IAC motor windings causing the IAC motor shaft to move in and out a given distance for each pulse, (referred to as IAC counts on a scan tool). This movement controls airflow around the throttle plates, which in turn, controls engine idle speed, on either a hot or cold engine. IAC valve pintle position counts can be seen by using a scan tool. 0 counts corresponds to fully closed passage, while 140 counts or more (depending on application) corresponds to full flow. While the IAC valve controls airflow through the throttle body, (and thus idle speed) a minimum amount of air flow goes past the throttle plates. The throttle plate position is set by the throttle stop screw and plugged at the factory to avoid unnecessary tampering. DIAGNOSTIC NOTES: ^ If the IAC valve is disconnected and reconnected with the engine running, the idle rpm may be wrong. In this case, the IAC has to be reset. ^ When servicing the IAC, it should only be disconnected or connected with the ignition OFF. This will keep from having to reset the IAC. ^ For diagnosis and testing procedures, see COMPUTERIZED ENGINE CONTROLS. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Testing and Inspection > Idle Air Control (IAC) Reset Procedure Idle Speed/Throttle Actuator - Electronic: Testing and Inspection Idle Air Control (IAC) Reset Procedure To reset the Idle Air Control (IAC) valve pintle position, proceed with the following: 1. Block the drive wheels, and apply the parking brake. Select "Engine rpm" on "Scan" tool. 2. Start the engine, and hold the engine speed above 2000 rpm. Select "Field Service Mode" for ten seconds (this will reset the IAC valve pintle position). 3. Exit "Field Service Mode," and allow the engine to return to idle. 4. Turn the ignition "OFF," then restart the engine and check for the proper idle operation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Testing and Inspection > Idle Air Control (IAC) Reset Procedure > Page 2145 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection Idle Air Control (IAC) System Check (Chart C-2C) Chart C-2C Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Testing and Inspection > Idle Air Control (IAC) Reset Procedure > Page 2146 Wiring Diagram For IAC System CIRCUIT DESCRIPTION: The ECM controls engine idle speed with the Idle Air Control (IAC) valve. To increase idle speed, the ECM retracts the IAC valve pintle away from its seat, allowing more air to pass by the throttle body. To decrease idle speed, it extends the IAC valve pintle towards its seat, reducing bypass air flow. A "Scan" tool will read the ECM commands to the IAC valve in counts. The higher the counts indicate more air bypass (higher idle). The lower the counts indicate less air is allowed to bypass (lower idle). TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. 1. The IAC tester is used to extend and retract the IAC valve. Valve movement is verified by an engine speed change. If no engine speed occurs, the valve can be retested when removed from the throttle body. 2. This step checks the quality of the IAC movement in step 1. Between 700 and 1500 rpm, the engine speed should change smoothly with each flash of the tester light for both extend and retract. If the IAC valve is retracted beyond the control range (approximately 1500 rpm), it may take many flashes in the extend position before the engine speed drops. This is normal on certain engines; fully extending the IAC may cause the engine to stall. 3. Steps 1 and 2 verified proper IAC valve operation. This step checks the IAC circuit. Each lamp on the node light should flash red and green while the IAC valve is cycled. While the sequence of colors are not important, if either the light is "OFF" or does not flash red and green, check the circuits for faults. Check for poor terminal contacts. DIAGNOSTIC AIDS: A slow, unstable idle may be caused by a non-IAC system problem that cannot be overcome by the IAC valve. Out of control range IAC "Scan" tool counts will be above 60 if idle is too low, and "0" counts if the idle is too high. If the idle speed is too high, turn the ignition "OFF" to stop the engine. Turn the ignition "ON" without the engine running. Wait 45 seconds for the IAC valve pintle to seat, then disconnect the IAC valve. The following checks should be made to repair a non-IAC system problem: a. Vacuum leak (High Idle) - If idle is too high, stop the engine. Fully extend (low) IAC with tester. Start engine. If idle speed is above 800 rpm, locate and correct vacuum leak including PCV system. Also check for binding of throttle blade or linkage. b. System Too Lean (High Air/Fuel Ratio) - The idle speed may be too high or too low. Engine speed may vary up and down and disconnecting the IAC valve does not help. A Code 44 may set. "Scan" O2 voltage will be less than 300 mv (0.3 volt). Check for low regulated fuel pressure , or water in fuel. A fixed oxygen sonsor voltage above 800 mv (0.8 volts) may be contaminated by silicone. A Code 45 may be stored in the computer. c. System Too Rich (Low Air/Fuel Ratio - The idle speed will be too low. Scaning IAC counts will usually be above 80. System is obviously rich and may exhibit black smoke in exhaust. "Scan" tool O2 voltage will be fixed above 800 mv (0.8 volt). Check for high fuel pressure, leaking or sticking injector. Silicone contaminated O2 sensors "Scan" voltage will be slow to respond. d. Throttle Body - Remove IAC valve and inspect bore for foreign material. e. IAC Valve Electrical Connections - IAC valve harness connections should be carefully checked for proper contact. f. PCV Valve - An incorrect or faulty PCV valve may result in an incorrect idle speed. g. Refer to "Rough, Unstable, Incorrect Idle or Stalling" in DIAGNOSIS BY SYMPTOM. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Testing and Inspection > Page 2147 Idle Speed/Throttle Actuator - Electronic: Adjustments NOTE: The minimum idle air rate is set at the factory with a stop screw, which is covered with a tamper plug. This setting allows enough air flow by the throttle valves to cause the IAC valve pintle to be positioned a calibrated number of steps (counts), from the seat, during "controlled" idle operation. If the IAC valve is disconnected and reconnected with the engine running, the idle speed may be wrong. In this case, the IAC valve can be reset by doing the following: The IAC valve will be reset by the computer when the vehicle speed exceeds 43 MPH while the engine speed is above 2000 RPM or when the diagnostic test connector is grounded when the engine RPM is above 2000 RPM. To reset the Idle Air Control (IAC) valve pintle position, proceed with the following: 1. Block the drive wheels, and apply the parking brake. Select "Engine rpm" on "Scan" tool. If a scan tool is not available, use a tachometer. 2. Start the engine, and hold the engine speed above 2000 rpm. Select "Field Service Mode" for ten seconds (this will reset the IAC valve pintle position). If a scan tool is not available, jumper pins A to B on the ALDL diagnostic connector. 3. Exit "Field Service Mode," (or remove jumper from ALDL connector) and allow the engine to return to idle. 4. Turn the ignition "OFF," then restart the engine and check for the proper idle operation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Service and Repair > Computer Command Control - Throttle Body Fuel Injection Idle Speed/Throttle Actuator - Electronic: Service and Repair Computer Command Control Throttle Body Fuel Injection To reset the Idle Air Control (IAC) valve pintle position, proceed with the following: 1. Block the drive wheels, and apply the parking brake. Select "Engine rpm" on "Scan" tool. 2. Start the engine, and hold the engine speed above 2000 rpm. Select "Field Service Mode" for ten seconds (this will reset the IAC valve pintle position). 3. Exit "Field Service Mode," and allow the engine to return to idle. 4. Turn the ignition "OFF," then restart the engine and check for the proper idle operation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Service and Repair > Computer Command Control - Throttle Body Fuel Injection > Page 2150 Idle Speed/Throttle Actuator - Electronic: Service and Repair Idle Air Control (IAC) Valve Replacement Model 700 TBI - Exploded View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Service and Repair > Computer Command Control - Throttle Body Fuel Injection > Page 2151 Flange Mounted IAC Valve REMOVAL: 1. Verify that the ignition switch is in the OFF position. 2. Disconnect the electrical connector. 3. Remove the IAC valve assembly and O-ring, discard O-ring. CAUTION: On IAC valves that have been in service, Do Not push or pull on the IAC valve pintle. The force required to move the pintle may damage the threads on the worm drive. Do Not soak the IAC valve in any liquid solvent or cleaner, as damage may result. NOTE: ^ Clean the IAC valve gasket sealing surface, pintle valve seat, and air passage: a. Use carburetor cleaner to remove carbon deposits. Do Not use a cleaner that contains Methyl Ethyl Ketone. It is an extremely strong solvent, and not necessary for this type of deposit. b. Shiny spots on the pintle or pintle seat are normal, and do not indicate misalignment or a bent pintle shaft. c. If the air passage has heavy deposits, remove the throttle body for complete cleaning. ^ If installing a new IAC valve, be sure to replace with an identical part. IAC valve pintle shape and diameter are designed for the specific application. INSTALLATION: 1. If installing a new IAC valve: a. Measure the distance between the tip of the IAC valve pintle and the mounting surface. b. If greater than 28 mm, use finger pressure to slowly retract the pintle. The force required to retract the pintle of a new valve will not cause damage to the valve. 2. Install the IAC valve assembly with a new O-ring, and reinstall IAC valve assembly, making sure that attaching screws are coated with appropriate thread locking compound. 3. Connect the electrical connector. 4. Reset the IAC valve pintle position: ^ The IAC valve will be reset by the computer when the vehicle speed exceeds 43 MPH while the engine speed is above 2000 RPM or when the diagnostic test connector is grounded when the engine RPM is above 2000 RPM. 5. Test drive the vehicle and check for proper idle operation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Service and Repair Malfunction Indicator Lamp: Service and Repair The check engine lamp will be illuminated when the ignition switch is placed in the On position. When the engine is started, the lamp should go off. If the lamp remains On for 10 seconds or constantly after the engine is started, the self diagnosis system has detected a problem and has stored a code in the system Electronic Control Module (ECM). After diagnosis and repair, the ECM memory can be cleared of codes as follows: On models except Cadillac with DEFI and 1986-88 Buick Reatta/Riviera and Oldsmobile Toronado/Trofeo, remove the ECM fuse or disconnect the battery ground cable for approximately 30 seconds, with ignition switch in the Off position. It should be noted, if battery ground cable is disconnected to clear codes, components such as clocks, electronically tuned radios etc., will have to be reset. On vehicle that are equipped as such, the ECM power feed is connected by a pigtail, inline fuse holder, at the positive battery terminal. To clear codes within the ECM system and protect the components that need resetting, disconnect the inline fuse. On 1980-85 Cadillac models with DEFI engines, depress Electronic Climate Control Off and Hi buttons to clear codes. On 1986-92 Cadillac DeVille and Fleetwood models, depress Off and Lo button on the Electronic Climate Control to clear stored BCM codes. Depress Off and Hi to clear stored ECM codes. On Cadillac Eldorado and Seville and 1986-88 Buick Reatta/Riviera and Oldsmobile Toronado/Trofeo models, the stored codes are cleared during the self-diagnostic procedure. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Voltage 3.6 to 5.2 V at 1000 to 2000 ft Note: Note: Apply 10 in. Hg to MAP SENSOR at given altitude and watch voltage. It should drop 1.0 to 1.5 Volts from Voltage Specification given. 3.5 to 5.1 V at 2000 to 3000 ft 3.3 to 5.0 V at 3000 to 4000 ft 3.2 to 4.8 V at 4000 to 5000 ft 3.0 to 4.6 V at 5000 to 6000 ft 2.9 to 4.5 V at 6000 to 7000 ft 2.8 to 4.3 V at 7000 to 8000 ft 2.6 to 4.2 V at 8000 to 9000 ft 2.5 to 4.0 V at 9000 to 10000 ft Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2161 Manifold Pressure/Vacuum Sensor: Locations Engine Component Locations. RH Front Of Dash, LH Side Of Blower Motor Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2162 Manifold Pressure/Vacuum Sensor: Description and Operation Map Sensor The Manifold Absolute Pressure (MAP) sensor measures changes in the intake manifold pressure resulting from engine load and speed changes. The computer sends a 5.0 volt reference signal to the MAP sensor. As pressure changes in the intake manifold occur, the electrical resistance of the MAP sensor also changes. By monitoring the sensor output voltage, the computer can determine the manifold absolute pressure. The higher the MAP voltage output the lower the engine vacuum, which requires more fuel. The lower the MAP voltage output the higher the engine vacuum, which requires less fuel. Under certain conditions, the MAP sensor is also used to measure barometric pressure. This allows the computer to automatically adjust for different altitudes. The computer uses the MAP sensor to control fuel delivery and ignition timing. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2163 Manifold Pressure/Vacuum Sensor: Testing and Inspection Chart C-1D Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2164 Wiring Diagram For MAP Sensor CIRCUIT DESCRIPTION: The Manifold Absolute Pressure (MAP) sensor responds to changes in manifold pressure (vacuum). The ECM sends a five volt reference to the MAP sensor. As manifold pressure changes, the output voltage of the sensor also changes. By monitoring the sensor output voltage, the ECM knows the manifold pressure. A lower pressure output voltage will be approximately 1.0-2.0 volts at idle. Higher pressure output voltage will be approximately 4.0-4.8 volts at Wide Open Throttle (WOT). The MAP sensor is also used, under certain conditions, to measure barometric pressure. This allows the ECM to make engine adjustments for different altitudes. The ECM uses the MAP sensor information to control fuel delivery and ignition timing. TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. 1. When comparing "Scan" readings to a known good vehicle, it is important to compare vehicles that use a MAP sensor having the same color insert or having the same "Hot Stamped" number. 2. Applying 34 kPa (10" Hg.) of vacuum to the MAP sensor should cause the voltage to change. The voltage value should be greater than 1.5 volts. Upon applying vacuum to the sensor, the change in voltage should be instantaneous. A slow voltage change indicates a faulty sensor. 3. Check vacuum hose to sensor for a leak or a restriction. Be sure that no other vacuum devices are connected to the MAP sensor hose. 4. Disconnect sensor from the bracket and twist sensor by hand to check for an intermittent connection. Output changes greater than 0.1 volt indicate a bad connector or connection. If OK, replace the sensor. NOTE: Make sure electrical connector remains securely fastened, and the same diagnostic test equipment is used on all measurements. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Memory Calibration Unit > Component Information > Technical Service Bulletins > PROM/MEMCAL - Identification Marks Memory Calibration Unit: Technical Service Bulletins PROM/MEMCAL - Identification Marks File In Section: 6E - Engine Fuel & Emission Bulletin No.: 44-65-01 Date: October, 1994 Subject: New PROM/MEMCAL Identification Markings Models: 1995 and Prior Passenger Cars and Trucks Note: For the purposes of this document, the terms PROM and MEMCAL will be used interchangeably. To simplify identification of service PROMs. a new external marking format will be implemented. Parts manufactured after Sept. 1994 will feature these new markings. This change will place the full 8-digit service part number on the PROM, in place of the old 4-digit "EXTERNAL ID" number. In the past, parts and service personnel could not identify a PROM without using a cross-reference table that matched external IDs and service numbers. In the future, the cross-reference table will not be required for PROMs; parts will be ordered directly from the number appearing on the PROM. However, the label will retain the broadcast code alpha characters to allow continued use of cross-reference charts, if so desired. Old Marking Format: New Marking Format: ^ Ordering the above PROM from the old marking format would require using a cross-reference chart to determine a service part number, based on the BROAD CAST CODE and EXTERNAL ID NUMBERS. ^ To order from the new format, simply combine the 2nd and 3rd lines to form an 8-digit part number that can be directly ordered from SPO (number 16134624 in the above example). As these changes are phased into the parts inventory, it should be noted that dealers will continue to see parts with both formats for some time in the future. This is because: ^ Millions of vehicles have already been built with the old format. ^ SPO has existing stock of MEMCALs and PROMs with the old format. ^ PROMS with 7-digit part numbers (representing less than 10% of current part numbers) will continue to use the old format. The 7-digit part numbers are easily identified because they always begin with "122xxxx". Due to manufacturing processes, more than one 8-digit part number may appear on a MEMCAL. In this event, service personnel should use the label on the exterior cover of the MEMCAL assembly. To avoid confusion, only the service label will include the BROAD CAST CODE, consisting of letter characters (I.E., ARCL). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Memory Calibration Unit > Component Information > Technical Service Bulletins > PROM/MEMCAL - Identification Marks > Page 2169 CHANGES TO MEMCAL/PROM LABELING FORMATS ^ MEMCALs may use either INK-JET or ADHESIVE labels, as shown. ^ PROMs will always use ADHESIVE labels with the same format as shown for MEMCALs. These changes will become effective on parts manufactured after 10/94. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Quad Driver <--> [Output Driver] > Component Information > Locations Quad Driver: Locations Quad/Output drivers are hard wired onto the ECM/PCM/VCM. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Quad Driver <--> [Output Driver] > Component Information > Locations > Page 2173 Quad Driver: Description and Operation Quad/Output Driver Module The Control Module in this vehicle controls most components with electronic switches which complete a ground circuit when turned on. When the switches are arranged in groups of 4, they can independently control up to 4 outputs and are called Quad Drivers. When the switches are arranged in groups of 7, they can independently control up to 7 outputs and are called Output Drivers. Not all outputs are always used. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Quad Driver <--> [Output Driver] > Component Information > Locations > Page 2174 Quad Driver: Testing and Inspection Little or no quad driver testing was supplied by the manufacturer. The engine module decides when to turn each switch of the driver "ON". Even though some models will set codes, in the end, if you want to check the driver itself, you'll need: 1. To use a scantool to command the suspected driver switch to energize (ground) the circuit, while checking with a test light, 2. To operate the vehicle in a way that should cause the suspected portion of the driver to switch "ON". On the up side, since the early 90's, most driver load circuits utilized circuit breakers. This protected most drivers and engine models from burning up when the circuit was overloaded. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Quad Driver <--> [Output Driver] > Component Information > Locations > Page 2175 Quad Driver: Service and Repair Quad/Output drivers are hard wired onto the ECM/PCM/VCM, and can't be serviced separately. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensors - Silica Contamination Oxygen Sensor: Technical Service Bulletins Oxygen Sensors - Silica Contamination Model Year: 1981 Bulletin No: 81-I-37 File In Group: 60 Number: 11 Date: Feb. 81 Subject: Silica Contamination of Oxygen Sensors and Gelation of Oil. Models Affected: All Oxygen sensor performance can deteriorate if certain RTV silicone gasket materials are used. Other RTV's when used with certain oils, may cause gelation of the oil. The degree of performance severity depends on the type of RTV and application of the engine involved. Therefore, when repairing engines where this item is involved, it is important to use either cork composition gaskets or RTV silicone gasket material approved for such use. GMS (General Motors Sealant) or equivalent material can be used. GMS is available through GMPD with the following part numbers: 1052366 3 oz. 1052434 10.14 oz. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2180 Oxygen Sensor: Specifications MINIMUM IDLE SPEED Transmission Gear Idle Speed IAC Counts Open/Closed Loop (2) Auto. D 600 +/-50 (1) CL Man. N 600 +/-50 (1) CL (1) No IAC counts are provided for this vehicle. (2) Let engine idle until proper fuel control status is reached (open/closed loop). TORQUE VALUES EGR valve bolts.................................................................................................................................... .............................................11-18 lb.ft. (15-25 N-m) Oxygen sensor..................................................................................................................................... ..........................................................30 lb.ft. (41 N-m) Throttle Body attaching bolts................................................................................................................ ........................................................18 lb.ft. (25 N-m) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2181 Oxygen Sensor: Locations Engine Component Locations. Front Of Engine, In Exhaust Manifold Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2182 LH Front Of 2.2L Front Of Engine, In Exhaust Manifold Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2183 Oxygen Sensor: Description and Operation Oxygen Sensor The oxygen sensor is located in the exhaust system. The sensor monitors atmospheric air versus exhaust gas oxygen content to produce a voltage output. This voltage ranges from approximately 0.1 volt (high oxygen - lean mixture) to 0.9 volt (low oxygen - rich mixture). By monitoring the oxygen sensor output voltage, the computer can determine the amount of oxygen in the exhaust gas and adjust the air/fuel mixture accordingly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2184 Oxygen Sensor: Service and Repair The oxygen sensor has a permanently attached wire and connector. This should not be removed, since the removal will affect proper operation of the oxygen sensor. 1. Disconnect electrical connector from oxygen sensor. 2. Using a suitable oxygen sensor wrench, carefully remove the sensor from exhaust manifold or pipe. The oxygen sensor may be difficult to remove when engine temperature is below 120°F. Use CAUTION, since excessive force may damage threads in exhaust manifold or pipe. 3. If a new sensor is being used, install the new sensor into the manifold or pipe. 4. If an old sensor is being reused, coat threads with anti-seize compound, then install the sensor into the manifold or pipe. 5. Torque the oxygen sensor to specifications, then reconnect the electrical connector. See MECHANICAL SPECIFICATIONS for sensor torque specifications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations RH Rear Of Engine Compartment. LH Front Of Dash, Below Brake Booster Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2188 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch The Power Steering Pressure Switch (PSPS) opens during high pressure power steering situations. When the power steering switch is open, power to the A/C relay is shut off, resulting in air conditioning compressor clutch disengagement. A signal is also sent to the ECM. The ECM uses this signal for idle speed control. A Scan tool should read "off" normally, and "on" with high pressure. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 2194 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 2195 Engine Control Module: Technical Service Bulletins ECM/PCM - Damage Prevention Number: 91-318-6E Section: 6E Date: MAY 1991 Corp. Bulletin No.: 176502R Subject: DAMAGE TO ECM/PCM CIRCUIT BOARD WHEN INSTALLING A MEM-CAL Model and Year: 1986-91 ALL PASSENGER CARS AND TRUCKS CONDITION: When installing a service replacement ECM/PCM, the use of incorrect MEMCAL installation procedures may cause the ECM/PCM to fail before it can be installed in the vehicle. This condition may appear as if the ECM/PCM were defective when it was shipped to the dealership, when in fact it was damaged while being installed. In addition this condition may also occur when installing an "updated" service MEM-CAL into the vehicles original equipment ECM/PCM. CAUSE: Excessive vertical force may be applied to the MEM-CAL resulting in flexing of the circuit board and damage to the connections between the circuit board and attached components. Excessive verticle force may be generated in two ways. 1. Incorrect MEM-CAL installation procedure. 2. Interference between MEM-CAL and cover. CORRECTION: Use the following procedure. Service Procedure: Important: This procedure supersedes any instructions regarding MEM-CAL installation dated prior to September 1990. 1. Inspect the MEM-CAL to determine if a cork spacer is glued to the top side of the MEM-CAL assembly. If so, remove it prior to installation. 2. Align small notches with matching notches in the ECM/PCM MEM-CAL socket. 3. VERY GENTLY press down on the ends of the MEM-CAL until the locking levers are rotated toward the sides of the MEM-CAL. Notice: To avoid ECM/PCM damage, do not press on the ends of the MEM-CAL until the levers snap into place. Do not use any vertical force beyond the minimum required to engage the MEM-CAL into its socket. 4. While continuing light pressure on the ends of MEM-CAL, use your index fingers to press the locking levers inward until they are snapped into place. Listen for click. 5. Install MEM-CAL cover and install ECM/PCM in vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 2196 Engine Control Module: Technical Service Bulletins ECM/PCM - Damaged and/or Misdiagnosed Number: 91-384-6E Section: 6E Date: AUGUST 1991 Corporate Bulletin No.: 176503 Subject: DAMAGED ECM/PCM AND/OR MIS-DIAGNOSED ECM/PCM SYMPTOMS DUE TO INCORRECT "TAP-TESTING" PROCEDURES Model and Year: 1982-91 ALL PASSENGER CARS AND TRUCKS CONDITION: Because of the intermittent nature of some Electronic Control Module (ECM) or Powertrain Control Modules (PCM) symptoms, some service technicians have been subjecting the ECM/PCM to vibration and/or shock testing. Commonly known as tap-testing, this procedure involves tapping on the ECM/PCM case, while the engine is running. It is generally accepted that if the engine or ECM/PCM falters due to the tapping, an intermittent internal ECM/PCM defect may be indicated. However, this may not always be true. If too much force is applied to the ECM/PCM during the test the following symptoms may result: ^ Immediate ECM/PCM failure. ^ ECM/PCM suffers damage which may cause a failure at a later date. ^ ECM/PCM Reset (or Glitch), creating a momentary stall, miss Service Engine Soon (SES) light and/or loss of serial data. CAUSE: The ECM/PCM should be tapped using only the fingertips of one hand. Use of the palm, fist, or any type of tool subjects the ECM/PCM to forces that can cause both the circuit board and the outer aluminum case to flex and distort beyond design limits. The Integrated Circuits (IC) used in today's ECM/PCMs are mounted to the circuit board using a mounting process referred to as "surface technology." There are no circuit board holes for IC leads to go through. The IC leads set on pads, (28 pads or 52 pads depending on the IC) and solder is flowed around the leads to make the electrical connection to the circuit board. ^ Any flexing of the circuit board, beyond design limits, places the IC solder connections at risk of damage. Such damage may be apparent immediately, or it may appear at a future date. Circuit board deflection can occur as a result of striking the ECM/PCM, using ONLY THE PALM OF THE HAND. ^ If struck on the bottom side (the side opposite the service label), the ECM/PCM's aluminum outer case may deflect inward far enough to contact the electrical leads attached to the circuit board. Once in contact with the case the ECM/PCM electrical components will be shorted directly to ground. Although such shorting certainly has the potential to damage the ECM/PCM, it may not be permanent damage, depending on which circuit is involved. However, even if permanent damage is avoided, a short on any of the circuits will cause a disruption of normal ECM/PCM operation for the instant that the short occurs. This disruption may cause the ECM/PCM to reset (see "reset" above), creating the false impression that it is vibration sensitive or faulty. Reset is the ECM/PCM's normal way of coping with large voltage spikes. An ECM/PCM reset does not indicate that the ECM/PCM is defective or faulty, only that it is being subjected to abnormal conditions. CORRECTION: 1. TAP THE ECM/PCM ONLY ON THE TOP SIDE (The top side is where the service label is located.) ^ This will minimize the chance of deflecting the ECM/PCM case into the electrical leads on the circuit board. The clearance between the case and the circuit board is closest on the bottom side of the ECM/PCM. 2. TAP THE ECM/PCM USING ONLY THE FINGERTIPS - NO TOOLS. ^ To avoid excessive case deflection, avoid tapping in the center of the case. Tapping close to the edge of the ECM/PCM, especially in the corners, is best. ^ While using greater force may seem more effective, the test itself may cause the ECM/PCM to fail. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications Engine Control Module: Specifications Computer Terminal Voltage Specifications ECM Connector Terminal End View WIRE COLOR ABBREVIATION BLACK BLK Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 2199 BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 2200 Engine Control Module: Specifications ECM Terminal Identification & Voltage Specifications ECM Connector Terminal End View WIRE COLOR ABBREVIATION BLACK BLK Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 2201 BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Specifications > Computer Terminal Voltage Specifications > Page 2202 ECM Connector Terminal End View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Specifications > Page 2203 ECM Located In Passenger Compartment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Specifications > Page 2204 ECM Connector Terminal End View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control Module (ECM) Engine Control Module: Description and Operation Electronic Control Module (ECM) Closed Loop Operation ECM And PROM Access Cover The Electronic Control Module (ECM) is located in the passenger compartment and is the control center of the Computer Command Control (C3) system. The ECM constantly receives information from various sensors. The computer performs the diagnostic functions of the system. The computer can recognize operational problems and alert the driver through the "SERVICE ENGINE SOON" light. The computer stores a trouble code which identifies the problem area to diagnose and repair. The computer is designed to process the various input information, and send the necessary electrical response to control fuel delivery, spark control, and other emission control systems. The computer used in these vehicles is a type called GMP4. The computer can control these devices through the use of Quad Driver Modules (QDM). When the ECM is commanding a device or a component "ON," the voltage potential of the output is "LOW" or near zero volts. When the ECM is commanding a device or component "OFF," the voltage potential of the circuit will be "HIGH," or near 12 volts. The primary function of the QDM is to supply the ground for the component being controlled. The input information has an interrelation between sensor output. If one of the input devices failed, such as the oxygen sensor, this could affect more than one of the systems controlled by the computer. The computer has a learning ability which allows it to make corrections for minor variations in the fuel system to improve driveability. If the battery is disconnected to clear trouble codes or for repair, the learning process has to begin all over again, and a change may be noticed in the driving performance of the vehicle. To reset the vehicles learning ability, make sure the engine is at operating temperature and operate the vehicle at part throttle, moderate acceleration, and idle conditions, until normal performance returns. The ECM used in these vehicles uses an ECM with two serviceable parts. A controller called a ECM, without a PROM, and a PROM with specific programming information. NOTE: When a production ECM is replaced with a service ECM, it is important to transfer the broadcast code and production number from the original ECM to the service ECM. This allows for positive identification of ECM parts throughout the service life of the vehicle. DO NOT affix the information to the ECM cover. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control Module (ECM) > Page 2207 Engine Control Module: Description and Operation Throttle Body Fuel Injection Control Modules Powertrain Control Module (PCM) The Electronic Control Module (ECM) is located in the passenger compartment and is the control center of the Computer Command Control (C3) system. The ECM constantly receives information from various sensors. The computer performs the diagnostic functions of the system. The computer can recognize operational problems and alert the driver through the "SERVICE ENGINE SOON" light. The computer stores a trouble code which identifies the problem area to diagnose and repair. The computer is designed to process the various input information, and send the necessary electrical response to control fuel delivery, spark control, and other emission control systems. The computer can control these devices through the use of Quad Driver Modules (QDM). When the ECM is commanding a device or a component "ON," the voltage potential of the output is "LOW" or near zero volts. When the ECM is commanding a device or component "OFF," the voltage potential of the circuit will be "HIGH," or near 12 volts. The primary function of the QDM is to supply the ground for the component being controlled. The input information has an interrelation between sensor output. If one of the input devices failed, such as the oxygen sensor, this could affect more than one of the systems controlled by the computer. The computer has a learning ability which allows it to make corrections for minor variations in the fuel system to improve driveability. If the battery is disconnected to clear trouble codes or for repair, the learning process has to begin all over again, and a change may be noticed in the driving performance of the vehicle. To reset the vehicles learning ability, make sure the engine is at operating temperature and operate the vehicle at part throttle, moderate acceleration, and idle conditions, until normal performance returns. A vehicle equipped with a 4-cylinder engine has an ECM referred to as GMP4 with two parts for service. A controller which is the ECM itself, without a MEM-CAL, and a memory calibration unit called a MEM-CAL (PROM). Vehicles with a V-6 or V-8 cylinder engine have an ECM referred to as GMCM with three serviceable parts. A controller called a ECM, without a PROM, a PROM with specific programming information, and a CAL-PAK with specific engine specifications. NOTE: When a production ECM is replaced with a service ECM, it is important to transfer the broadcast code and production number from the original ECM to the service ECM. This allows for positive identification of ECM parts throughout the service life of the vehicle. DO NOT affix the information to the ECM cover. C3 Self Diagnostics ALDL Connector Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control Module (ECM) > Page 2208 Use a "Scan" tool or ground the diagnostic test terminal with the engine not running and the ignition switch in the "ON" position in order to retrieve codes. The "SERVICE ENGINE SOON" light will flash a Code 12 three times and then flash each code stored in memory three times, if the "Scan" tool is not used. Once all Codes are retrieved, a Code 12 will follow. New codes cannot be stored in the ECM once the diagnostics mode is activated. See DIAGNOSTIC CIRCUIT CHECK for a complete system check. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics Some control module's may have problems due to cracked solder joints on the circuit board. These internal control module problems can cause the following symptoms: ^ Failure to start or vehicle is stalling. ^ The "CHECK ENGINE" "SERVICE ENGINE SOON" or "MALFUNCTION INDICATOR" light will flash or light up, but no trouble codes will be present. ^ Vehicle instrument panel displays may be inoperative. ^ The control module may or may not communicate with the scanner. ^ Other intermittent driveability problems. Incorrect PROM or MEMCAL removal and replacement can create solder joint problems or aggravate an existing condition. See PROM or MEMCAL INSTALLATION for proper procedures. If a solder joint problem results in a "hard" failure, normal test procedures will usually pinpoint a faulty control module. Many symptoms caused by poor solder joints in the control module result in intermittent problems, but they may be hard to duplicate during troubleshooting. Control module's with solder joint problems are sensitive to heat and vibration. You can check for these internal control module problems in either, or both, of the following ways: ^ Remove the control module from its mounting bracket and extend it on the harness so that you can expose it to the vehicle heater ducts. Alternatively, use flexible ducting to route air from the heater to the control module location. Then run the engine and operate the heater at the "MAX HEAT" position. This exposes the control module to approximately 140°F. ^ With the engine running, tap on the control module several times with your hand or finger tips to simulate vehicle vibration. If the engine stumbles or stalls, the "CHECK ENGINE" "SERVICE ENGINE SOON" or "MALFUNCTION INDICATOR" light flashes, or any of the previous symptoms occur, the control module may have bad solder joints on the circuit board. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) Replacement Engine Control Module: Service and Repair Engine Control Module (ECM) Replacement ECM Located In Passenger Compartment. ECM And PROM Access Cover Prom Removal And Tool Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) Replacement > Page 2213 When replacing a production ECM with a service ECM, transfer the broadcast code and production number from the production unit to the service unit. Also, during replacement, the PROM must be removed from the ECM being replaced and transferred to the new unit. Some ECM's are equipped with another chip called a Cal-Pak. If the ECM if equipped with a Cal-Pak chip, it will be located next to the PROM and must be transferred along with the PROM. 1. Disconnect battery ground cable. 2. Then disconnect two computer electrical connectors. 3. Remove computer mounting hardware. 4. Remove computer from passenger compartment. 5. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) Replacement > Page 2214 Engine Control Module: Service and Repair Throttle Body Fuel Injection ECM Replacement When replacing a production ECM with a service ECM, transfer the broadcast code and production number from the production unit to the service unit. Also, during replacement, the PROM, CALPACK and if equipped, the MEMCAL must be removed from the ECM being replaced and transferred to the new unit. Refer to PROM, CALPAK, and MEMCAL for procedures. 1. Disconnect battery ground cable. 2. Then disconnect computer electrical connectors. 3. Remove computer mounting hardware. 4. Remove computer from passenger compartment. 5. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation Coolant Temperature Sensor (CTS) The engine coolant temperature sensor is a thermistor that is located in the engine coolant flow. When the coolant temperature is low, the sensor produces a high resistance. When the coolant temperature is high, the sensor produces a low resistance. The computer sends a 5.0 volt signal to the coolant temperature sensor through a resistor in the ECM and measures the voltage. The voltage will be high or low depending on coolant temperature. By varying the voltage, the computer will sense engine coolant temperature. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2223 Crankshaft Position Sensor: Mechanical Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2224 Rear Of Engine Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2225 Crankshaft Position Sensor: Description and Operation Typical DIS Crankshaft Sensor This crankshaft sensor is mounted remotely on the bottom side of the ignition module. This sensor protrudes into the block, within approximately 0.050" of the engine crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots cast into it, six of which are evenly spaced 60° apart. A seventh slot is spaced 10° from one of the other slots and serves to generate a "sync pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the crank pulses, the DIS module sends reference signals to the ECM which are used to indicate crankshaft position and engine speed. The ignition module will continue to send these reference pulses to the ECM at a rate of one for each 180° or crankshaft rotation. The ECM will activate the fuel injector based on the recognition of every other reference pulse beginning at a crankshaft position of 120° after top dead center. By comparing the time between pulses, the DIS module can recognize the pulse representing the seventh slot or "sync pulse," which starts the calculation of the ignition coil sequence. The second crank pulse following the "sync pulse" signals the "DIS" module to fire the #2/3 ignition coil and the fifth crank pulse signals the module to fire the #1/4 ignition coil. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Torque Valve Torque Valve Induction Air Sensor 44 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2229 Intake Air Temperature Sensor: Locations Top Rear Of 2.2L Top LH Rear Of Engine, In Air Cleaner Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2230 Intake Air Temperature Sensor: Description and Operation IAT Sensor (Typical) The Intake Air Temperature (IAT) sensor uses a thermistor to control the signal voltage to the ECM. The variable resistor changes its resistance based on temperature. Low intake air temperature produces high resistance, 100,000 ohms at -40°C (-40°F), while a high temperature causes low resistance, 70 ohms at 130°C (266°F). The ECM supplies a 5.0 volt signal to the IAT sensor through a resistor in the ECM and monitors the voltage change. By monitoring the voltage, the ECM calculates the air temperature and uses this data to assist in determining fuel delivery and spark advance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Voltage 3.6 to 5.2 V at 1000 to 2000 ft Note: Note: Apply 10 in. Hg to MAP SENSOR at given altitude and watch voltage. It should drop 1.0 to 1.5 Volts from Voltage Specification given. 3.5 to 5.1 V at 2000 to 3000 ft 3.3 to 5.0 V at 3000 to 4000 ft 3.2 to 4.8 V at 4000 to 5000 ft 3.0 to 4.6 V at 5000 to 6000 ft 2.9 to 4.5 V at 6000 to 7000 ft 2.8 to 4.3 V at 7000 to 8000 ft 2.6 to 4.2 V at 8000 to 9000 ft 2.5 to 4.0 V at 9000 to 10000 ft Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2237 Manifold Pressure/Vacuum Sensor: Locations Engine Component Locations. RH Front Of Dash, LH Side Of Blower Motor Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2238 Manifold Pressure/Vacuum Sensor: Description and Operation Map Sensor The Manifold Absolute Pressure (MAP) sensor measures changes in the intake manifold pressure resulting from engine load and speed changes. The computer sends a 5.0 volt reference signal to the MAP sensor. As pressure changes in the intake manifold occur, the electrical resistance of the MAP sensor also changes. By monitoring the sensor output voltage, the computer can determine the manifold absolute pressure. The higher the MAP voltage output the lower the engine vacuum, which requires more fuel. The lower the MAP voltage output the higher the engine vacuum, which requires less fuel. Under certain conditions, the MAP sensor is also used to measure barometric pressure. This allows the computer to automatically adjust for different altitudes. The computer uses the MAP sensor to control fuel delivery and ignition timing. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2239 Manifold Pressure/Vacuum Sensor: Testing and Inspection Chart C-1D Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2240 Wiring Diagram For MAP Sensor CIRCUIT DESCRIPTION: The Manifold Absolute Pressure (MAP) sensor responds to changes in manifold pressure (vacuum). The ECM sends a five volt reference to the MAP sensor. As manifold pressure changes, the output voltage of the sensor also changes. By monitoring the sensor output voltage, the ECM knows the manifold pressure. A lower pressure output voltage will be approximately 1.0-2.0 volts at idle. Higher pressure output voltage will be approximately 4.0-4.8 volts at Wide Open Throttle (WOT). The MAP sensor is also used, under certain conditions, to measure barometric pressure. This allows the ECM to make engine adjustments for different altitudes. The ECM uses the MAP sensor information to control fuel delivery and ignition timing. TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. 1. When comparing "Scan" readings to a known good vehicle, it is important to compare vehicles that use a MAP sensor having the same color insert or having the same "Hot Stamped" number. 2. Applying 34 kPa (10" Hg.) of vacuum to the MAP sensor should cause the voltage to change. The voltage value should be greater than 1.5 volts. Upon applying vacuum to the sensor, the change in voltage should be instantaneous. A slow voltage change indicates a faulty sensor. 3. Check vacuum hose to sensor for a leak or a restriction. Be sure that no other vacuum devices are connected to the MAP sensor hose. 4. Disconnect sensor from the bracket and twist sensor by hand to check for an intermittent connection. Output changes greater than 0.1 volt indicate a bad connector or connection. If OK, replace the sensor. NOTE: Make sure electrical connector remains securely fastened, and the same diagnostic test equipment is used on all measurements. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Oxygen Sensors - Silica Contamination Oxygen Sensor: Technical Service Bulletins Oxygen Sensors - Silica Contamination Model Year: 1981 Bulletin No: 81-I-37 File In Group: 60 Number: 11 Date: Feb. 81 Subject: Silica Contamination of Oxygen Sensors and Gelation of Oil. Models Affected: All Oxygen sensor performance can deteriorate if certain RTV silicone gasket materials are used. Other RTV's when used with certain oils, may cause gelation of the oil. The degree of performance severity depends on the type of RTV and application of the engine involved. Therefore, when repairing engines where this item is involved, it is important to use either cork composition gaskets or RTV silicone gasket material approved for such use. GMS (General Motors Sealant) or equivalent material can be used. GMS is available through GMPD with the following part numbers: 1052366 3 oz. 1052434 10.14 oz. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2245 Oxygen Sensor: Specifications MINIMUM IDLE SPEED Transmission Gear Idle Speed IAC Counts Open/Closed Loop (2) Auto. D 600 +/-50 (1) CL Man. N 600 +/-50 (1) CL (1) No IAC counts are provided for this vehicle. (2) Let engine idle until proper fuel control status is reached (open/closed loop). TORQUE VALUES EGR valve bolts.................................................................................................................................... .............................................11-18 lb.ft. (15-25 N-m) Oxygen sensor..................................................................................................................................... ..........................................................30 lb.ft. (41 N-m) Throttle Body attaching bolts................................................................................................................ ........................................................18 lb.ft. (25 N-m) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2246 Oxygen Sensor: Locations Engine Component Locations. Front Of Engine, In Exhaust Manifold Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2247 LH Front Of 2.2L Front Of Engine, In Exhaust Manifold Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2248 Oxygen Sensor: Description and Operation Oxygen Sensor The oxygen sensor is located in the exhaust system. The sensor monitors atmospheric air versus exhaust gas oxygen content to produce a voltage output. This voltage ranges from approximately 0.1 volt (high oxygen - lean mixture) to 0.9 volt (low oxygen - rich mixture). By monitoring the oxygen sensor output voltage, the computer can determine the amount of oxygen in the exhaust gas and adjust the air/fuel mixture accordingly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2249 Oxygen Sensor: Service and Repair The oxygen sensor has a permanently attached wire and connector. This should not be removed, since the removal will affect proper operation of the oxygen sensor. 1. Disconnect electrical connector from oxygen sensor. 2. Using a suitable oxygen sensor wrench, carefully remove the sensor from exhaust manifold or pipe. The oxygen sensor may be difficult to remove when engine temperature is below 120°F. Use CAUTION, since excessive force may damage threads in exhaust manifold or pipe. 3. If a new sensor is being used, install the new sensor into the manifold or pipe. 4. If an old sensor is being reused, coat threads with anti-seize compound, then install the sensor into the manifold or pipe. 5. Torque the oxygen sensor to specifications, then reconnect the electrical connector. See MECHANICAL SPECIFICATIONS for sensor torque specifications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations RH Rear Of Engine Compartment. LH Front Of Dash, Below Brake Booster Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2253 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch The Power Steering Pressure Switch (PSPS) opens during high pressure power steering situations. When the power steering switch is open, power to the A/C relay is shut off, resulting in air conditioning compressor clutch disengagement. A signal is also sent to the ECM. The ECM uses this signal for idle speed control. A Scan tool should read "off" normally, and "on" with high pressure. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2258 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor 18 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2259 Throttle Position Sensor: Locations Top Rear Of 2.2L Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 2L/4-134 Engine. 1991 Cavalier Engine Component Locations. Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2260 Throttle Position Sensor: Description and Operation Typical Throttle Position Sensor (TPS) Wiring Throttle Position Sensor PURPOSE The function of the Throttle Position Sensor (TPS) is to sense the current throttle valve position and relay that information to the ECM. Throttle position information allows the ECM to generate the required injector control signals (base pulse). OPERATION If the TPS senses a opening throttle, a voltage signal indicating this condition is sent to the ECM. The ECM then increases the injector pulse width, permitting increased fuel flow. As the throttle valve rotates in response to movement of the accelerator pedal, the throttle shaft transfers this rotation to the TPS. A potentiometer (variable resistor) within the TPS assembly changes its resistance (and voltage drop) in proportion to throttle movement. By applying a reference voltage (5.0 volts) to the TPS input, a varying voltage (reflecting throttle position) is available at the TPS output. For example, approximately 2.5 volts results from a 50% throttle valve opening (depending on TPS calibration). The voltage output from the TPS assembly is routed to the ECM for use in determining throttle position. If the TPS is held in a wide open throttle (WOT) position during engine start, the ECM will interpret this as a clear flood mode. The ECM will then pulse the injectors at a ratio of 20 to 1 in order to clear a flooded condition. The ECM will hold this injector rate as long as the throttle stays wide open, and the engine speed is below 600 rpm. LOCATION The Throttle Position Sensor (TPS), is mounted on the side of the throttle body opposite the throttle lever assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2261 Throttle Position Sensor: Adjustments TPS Adjustment Check The Throttle Position Sensor (TPS) is not adjustable. The normal closed throttle position voltage is below 1.33 volts, and normal wide open throttle position voltage is approximately 5.0 volts. If these limits are not in specification, check for freedom of throttle movement, and accelerator pedal interference from carpets and other obstructions. If the problem is not corrected, replace the TPS. The ECM has the ability to self zero the TPS voltage if it is below approximately 1.33 volts. A TPS voltage that does not fall within 0.33 volts and 1.33 volts should be replaced after checking connections. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2262 Throttle Position Sensor: Service and Repair Model 700 TBI - Exploded View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2263 Throttle Position Sensor REMOVAL: 1. Disconnect the electrical connector. 2. Remove TPS attaching screws. 3. Remove the TPS. CAUTION: The TPS is an electrical component and must not be soaked in any liquid cleaner or solvent, as damage may result. INSTALLATION: 1. With the throttle valve in the closed position, install the TPS on the throttle shaft. Rotate counter clockwise to align mounting holes. 2. Install the TPS attaching screws, finger tighten only. 3. Tighten attaching screws to 2.0 N-m (18 lb. in.) 4. Check TPS voltage: a. Connect a scan tool to the ALDL connector. b. Turn the ignition switch ON. c. Select TPS voltage display on the scan tool, and check voltage. The TPS voltage should be less than 1.25 volts. If the reading is higher than 1.25 volts, check for binding throttle valve or throttle cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Rear Of 3.1L Rear Of Engine, Top LH Side Of Transaxle Applicable to: 1L/V6-192 Engine. Cavalier w/Automatic Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2267 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch & Connector The PARK/NEUTRAL switch indicates to the computer when the transmission is in park or neutral. This information is used by the computer for ignition timing, Idle Air Control (IAC), and Transmission Torque Converter Clutch (TCC) operation. DO NOT drive the vehicle with the PARK/NEUTRAL switch disconnected, since idle quality may be affected. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2268 Transmission Position Switch/Sensor: Testing and Inspection Chart C-1A Wiring Diagram For P/N Switch CIRCUIT DESCRIPTION: The PARK/NEUTRAL switch contacts are closed to ground in park or neutral and open in drive ranges. The ECM supplies ignition voltage through a current limiting resistor to circuit 434, and senses a closed switch when the voltage on circuit 434 drops to less than one volt. The ECM uses the P/N signal as one of the inputs to control idle air and vehicle speed sensor diagnostics. TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2269 1. Checks for a closed switch to ground in the PARK position. Different makes of "Scan" tools will read PARK/NEUTRAL differently. Refer to operators manual for type of display used for a specific tool. 2. Checks for an open switch in drive range. 3. Be sure the "Scan" tool indicates drive even while wiggling the shifter to test for an intermittent or misadjusted switch in drive. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2270 Transmission Position Switch/Sensor: Adjustments 1. Place transaxle shift lever in NEUTRAL. 2. Loosen switch attaching screws. 3. Rotate switch on shaft assembly to align service adjustment hole with carrier tang hole. a. Insert 2.34 mm (3/32 inch) maximum diameter gauge pin to a depth of 15.0 mm (5/8 inch). 4. Tighten attaching screws. See SPECIFICATIONS/MECHANICAL for torque values. 5. Remove the gauge pin. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2271 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Start and Backup Lamp Switch 1. Remove negative battery cable, shift linkage, electrical connector, mounting bolts, and switch assembly. 2. Replacement using old or new switch. a. Place shift shaft in NEUTRAL. b. Align flats of shift shaft with switch. c. Old Switch only - Install mounting bolts-to-case, loosely. Insert gauge pin in service adjustment hole, and rotate switch until pin drops into a depth of 9.0 mm (9/64") and tighten bolts (see SPECIFICATIONS/MECHANICAL for torque values). d. New Switch only - Install mounting bolts and tighten. If bolt holes do not align with mounting boss on transaxle, verify that the shift shaft is in NEUTRAL; DO NOT rotate the switch. The switch is pinned in the NEUTRAL position. NOTE: If the switch has been rotated and the pin is broken, the switch can be adjusted using the old switch procedure and ADJUSTMENT PROCEDURES. 3. See ADJUSTMENT PROCEDURES for PARK/NEUTRAL switch adjustment. 4. After the switch is installed, verify that the engine will start only in PARK (A/T) or NEUTRAL (M/T). If the engine starts in any other position, readjust the switch using old switch procedure and ADJUSTMENT PROCEDURES. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Engine Component Locations. Top RH Rear Of Transaxle Applicable to: 1991 Cavalier w/2.2L/4-134 Rear Of 2.2 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2275 Top RH Rear Of Transaxle Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2276 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor The Vehicle Speed Sensor (VSS) is made up of a coil, which is mounted on the transmission, and a tooth rotor which is mounted to the output shaft in the transmission. As each rotor tooth nears the coil, the coil produces an Alternating Current (AC) voltage pulse. As the vehicle speed increases, the number of AC voltage pulses increase. The Digital Ratio Adapter Controller (DRAC) processes input from the VSS sensor and output signals from the speedometer, computer, and cruise control module. The DRAC takes the voltage pulses from the VSS sensor and uses them to open and close four solid state output switches to ground at a rate proportional to vehicle speed. The DRAC is matched to the vehicle based on final drive ratio and tire size. It is important to make sure the correct DRAC module is replaced on the vehicle if replacement is necessary. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Shift Light > Component Information > Testing and Inspection Shift Light: Testing and Inspection Chart C-8B Wiring Diagram For M/T Shift Light CIRCUIT DESCRIPTION: The shift light indicates the best transmission shift point for maximum fuel economy. The light is controlled by the ECM and is energized by grounding circuit 456. The ECM uses the measured engine and the vehicle speeds to calculate what gear the vehicle is in. It's this calculation that determines when the shift light should be energized. The ECM uses information from the following inputs to control the shift light: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Shift Light > Component Information > Testing and Inspection > Page 2280 1. Coolant temperature Sensor (CTS) 2. Throttle Position Sensor (TPS) 3. Vehicle Speed Sensor (VSS) 4. Engine Speed TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. 1. This should not turn "ON" the shift light. If the light is "ON", there is a short to ground in wiring circuit 456, or a fault in the ECM. 2. When the diagnostic terminal is grounded, the ECM should ground circuit 456. This should turn "ON" the shift light. 3. This checks the shift light circuit up to the ECM connector. If the shift light illuminates, then the ECM connector is faulty or the ECM does not have the ability to ground the circuit. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2285 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor 18 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2286 Throttle Position Sensor: Locations Top Rear Of 2.2L Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 2L/4-134 Engine. 1991 Cavalier Engine Component Locations. Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2287 Throttle Position Sensor: Description and Operation Typical Throttle Position Sensor (TPS) Wiring Throttle Position Sensor PURPOSE The function of the Throttle Position Sensor (TPS) is to sense the current throttle valve position and relay that information to the ECM. Throttle position information allows the ECM to generate the required injector control signals (base pulse). OPERATION If the TPS senses a opening throttle, a voltage signal indicating this condition is sent to the ECM. The ECM then increases the injector pulse width, permitting increased fuel flow. As the throttle valve rotates in response to movement of the accelerator pedal, the throttle shaft transfers this rotation to the TPS. A potentiometer (variable resistor) within the TPS assembly changes its resistance (and voltage drop) in proportion to throttle movement. By applying a reference voltage (5.0 volts) to the TPS input, a varying voltage (reflecting throttle position) is available at the TPS output. For example, approximately 2.5 volts results from a 50% throttle valve opening (depending on TPS calibration). The voltage output from the TPS assembly is routed to the ECM for use in determining throttle position. If the TPS is held in a wide open throttle (WOT) position during engine start, the ECM will interpret this as a clear flood mode. The ECM will then pulse the injectors at a ratio of 20 to 1 in order to clear a flooded condition. The ECM will hold this injector rate as long as the throttle stays wide open, and the engine speed is below 600 rpm. LOCATION The Throttle Position Sensor (TPS), is mounted on the side of the throttle body opposite the throttle lever assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2288 Throttle Position Sensor: Adjustments TPS Adjustment Check The Throttle Position Sensor (TPS) is not adjustable. The normal closed throttle position voltage is below 1.33 volts, and normal wide open throttle position voltage is approximately 5.0 volts. If these limits are not in specification, check for freedom of throttle movement, and accelerator pedal interference from carpets and other obstructions. If the problem is not corrected, replace the TPS. The ECM has the ability to self zero the TPS voltage if it is below approximately 1.33 volts. A TPS voltage that does not fall within 0.33 volts and 1.33 volts should be replaced after checking connections. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2289 Throttle Position Sensor: Service and Repair Model 700 TBI - Exploded View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2290 Throttle Position Sensor REMOVAL: 1. Disconnect the electrical connector. 2. Remove TPS attaching screws. 3. Remove the TPS. CAUTION: The TPS is an electrical component and must not be soaked in any liquid cleaner or solvent, as damage may result. INSTALLATION: 1. With the throttle valve in the closed position, install the TPS on the throttle shaft. Rotate counter clockwise to align mounting holes. 2. Install the TPS attaching screws, finger tighten only. 3. Tighten attaching screws to 2.0 N-m (18 lb. in.) 4. Check TPS voltage: a. Connect a scan tool to the ALDL connector. b. Turn the ignition switch ON. c. Select TPS voltage display on the scan tool, and check voltage. The TPS voltage should be less than 1.25 volts. If the reading is higher than 1.25 volts, check for binding throttle valve or throttle cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Rear Of 3.1L Rear Of Engine, Top LH Side Of Transaxle Applicable to: 1L/V6-192 Engine. Cavalier w/Automatic Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2294 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch & Connector The PARK/NEUTRAL switch indicates to the computer when the transmission is in park or neutral. This information is used by the computer for ignition timing, Idle Air Control (IAC), and Transmission Torque Converter Clutch (TCC) operation. DO NOT drive the vehicle with the PARK/NEUTRAL switch disconnected, since idle quality may be affected. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2295 Transmission Position Switch/Sensor: Testing and Inspection Chart C-1A Wiring Diagram For P/N Switch CIRCUIT DESCRIPTION: The PARK/NEUTRAL switch contacts are closed to ground in park or neutral and open in drive ranges. The ECM supplies ignition voltage through a current limiting resistor to circuit 434, and senses a closed switch when the voltage on circuit 434 drops to less than one volt. The ECM uses the P/N signal as one of the inputs to control idle air and vehicle speed sensor diagnostics. TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2296 1. Checks for a closed switch to ground in the PARK position. Different makes of "Scan" tools will read PARK/NEUTRAL differently. Refer to operators manual for type of display used for a specific tool. 2. Checks for an open switch in drive range. 3. Be sure the "Scan" tool indicates drive even while wiggling the shifter to test for an intermittent or misadjusted switch in drive. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2297 Transmission Position Switch/Sensor: Adjustments 1. Place transaxle shift lever in NEUTRAL. 2. Loosen switch attaching screws. 3. Rotate switch on shaft assembly to align service adjustment hole with carrier tang hole. a. Insert 2.34 mm (3/32 inch) maximum diameter gauge pin to a depth of 15.0 mm (5/8 inch). 4. Tighten attaching screws. See SPECIFICATIONS/MECHANICAL for torque values. 5. Remove the gauge pin. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2298 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Start and Backup Lamp Switch 1. Remove negative battery cable, shift linkage, electrical connector, mounting bolts, and switch assembly. 2. Replacement using old or new switch. a. Place shift shaft in NEUTRAL. b. Align flats of shift shaft with switch. c. Old Switch only - Install mounting bolts-to-case, loosely. Insert gauge pin in service adjustment hole, and rotate switch until pin drops into a depth of 9.0 mm (9/64") and tighten bolts (see SPECIFICATIONS/MECHANICAL for torque values). d. New Switch only - Install mounting bolts and tighten. If bolt holes do not align with mounting boss on transaxle, verify that the shift shaft is in NEUTRAL; DO NOT rotate the switch. The switch is pinned in the NEUTRAL position. NOTE: If the switch has been rotated and the pin is broken, the switch can be adjusted using the old switch procedure and ADJUSTMENT PROCEDURES. 3. See ADJUSTMENT PROCEDURES for PARK/NEUTRAL switch adjustment. 4. After the switch is installed, verify that the engine will start only in PARK (A/T) or NEUTRAL (M/T). If the engine starts in any other position, readjust the switch using old switch procedure and ADJUSTMENT PROCEDURES. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Engine Component Locations. Top RH Rear Of Transaxle Applicable to: 1991 Cavalier w/2.2L/4-134 Rear Of 2.2 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2302 Top RH Rear Of Transaxle Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2303 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor The Vehicle Speed Sensor (VSS) is made up of a coil, which is mounted on the transmission, and a tooth rotor which is mounted to the output shaft in the transmission. As each rotor tooth nears the coil, the coil produces an Alternating Current (AC) voltage pulse. As the vehicle speed increases, the number of AC voltage pulses increase. The Digital Ratio Adapter Controller (DRAC) processes input from the VSS sensor and output signals from the speedometer, computer, and cruise control module. The DRAC takes the voltage pulses from the VSS sensor and uses them to open and close four solid state output switches to ground at a rate proportional to vehicle speed. The DRAC is matched to the vehicle based on final drive ratio and tire size. It is important to make sure the correct DRAC module is replaced on the vehicle if replacement is necessary. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation Converter Types PRECAUTIONS CAUTION: Prolonged operation with a misfiring or flooded engine may cause the converter to overheat. This could cause damage either to the catalyst itself or the operating vehicle and possible personal injury. NOTICE: When jacking or lifting vehicle from frame side rails, be certain lift pads do not contact catalytic converter otherwise damage to converter may result. SYSTEM DESCRIPTION The catalytic converter is an emission control device added to the exhaust system to effectively reduce the levels of carbon monoxide, hydrocarbons, and in some cases oxides of nitrogen, exiting the tailpipe. The converter allows for a faster chemical reaction to take place and although it enters into the chemical reaction, it remains unchanged, ready to repeat Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 2308 the process. This device sometimes requires the use of heat shields, due to its high operating temperatures. The heat shields are necessary to protect chassis components, passenger compartment, and other areas from heat related damage. General Motors uses four different converter designs in conjunction with two types of catalysts. The four converter designs are: 1. Single bed monolith 2. Dual bed monolith 3. Single bed pellet 4. Dual bed pellet The two types of catalysts used are an Oxidation catalyst and a Three-Way (Oxidation/Reduction) catalyst. The Oxidation catalyst is coated with a material containing platinum and palladium which lowers levels of carbon monoxide and hydrocarbons. The Three-Way (Oxidation/Reduction) catalyst is coated with platinum and rhodium which lowers levels of oxides of nitrogen (NOx), as well as carbon monoxide and hydrocarbons. All dual bed converters, whether monolith or pellet type, contain both oxidation and three-way catalysts. A small diameter fuel tank filler neck is used on catalytic converter equipped vehicles to prevent the use of leaded fuel pump nozzles. Since the use of leaded fuels, or fuel additives containing lead, contaminates (damages) the catalysts, the use of unleaded fuels is mandatory on catalytic converter equipped vehicles. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 2309 Catalytic Converter: Testing and Inspection Proper diagnosis for a restricted exhaust system is essential before any components are replaced. The following procedure(s) may be used for diagnosis: Exhaust System Test at Oxygen Sensor CHECK AT 02 SENSOR: 1. Carefully remove O2 sensor. 2. Install Exhaust Backpressure Tester in place of 02 sensor. 3. After completing the diagnosis described below, be sure to coat threads of 02 sensor with anti-seize compound prior to re-installation. DIAGNOSIS: 1. With the engine idling at normal operating temperature, observe the exhaust system back pressure reading on the gauge. The reading should not exceed 1.25 psi (8.6 kPa). Increase engine speed to 2000 rpm and observe gauge. The reading should not exceed 3 psi (20.7 kPa). 2. If the back pressure exceeds the given specifications, a restricted exhaust system is indicated. 3. Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffler failure. 4. If there are no obvious reasons for the excessive backpressure, a restricted catalytic converter should be suspected, and replaced. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > System Information > Technical Service Bulletins > EVAP System - Service of Connectors Evaporative Emissions System: Technical Service Bulletins EVAP System - Service of Connectors File In Section: 06 - Engine/Propulsion System Bulletin No.: 00-06-04-021 Date: May, 2000 INFORMATION Subject: Proper Service of Quick Connect EVAP System Connectors Models: 1985-2001 Passenger Cars and Trucks The EVAP system must be serviced properly. Improper service of the EVAP system can cause EVAP system leaks and set an engine DTC. Important: DO NOT cut or kink EVAP hoses/pipes to service the EVAP system. A damaged, cut or kinked EVAP system hose/pipe must be replaced and NOT REPAIRED. To properly service the EVAP system, it is important to correctly identify the style of quick connect EVAP fitting used in the EVAP system. Correctly identifying the style of fitting will aid in the proper disconnection/connection of the fitting and the ability to reuse the fitting. Improper disconnection and/or connection of EVAP fittings can cause the following conditions and set engine DTCs: ^ Leaks in the EVAP system ^ Damage to the EVAP fitting(s) ^ Damage to and/or adversely effect the function of the EVAP components such as: - Purge solenoid - Canister - Vapor lines 1. To properly disconnect this style of fitting, slide the tab in and pull the fittings apart. 2. To reconnect this style of fitting, install the fittings back together and gently pull back on the fittings to verify proper connection of the fittings. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > System Information > Technical Service Bulletins > EVAP System - Service of Connectors > Page 2314 1. To properly disconnect this style of fitting, push in both sides of the retaining feature and pull the fittings apart. 2. To reconnect this style of fitting, install the fittings back together and gently pull back on the fittings to verify proper connection of the fittings. To properly disconnect this style of fitting, use the following procedure: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > System Information > Technical Service Bulletins > EVAP System - Service of Connectors > Page 2315 1. Move the tab of the retainer away from the male fitting in order to clear the retaining nub. 2. Move the tab of the retainer in the direction shown and pull the fittings apart. 3. To reconnect this style of fitting, install the fittings back together and gently pull back on the fittings to verify proper connection of the fittings. To properly service this style of fitting use the following procedure: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > System Information > Technical Service Bulletins > EVAP System - Service of Connectors > Page 2316 1. Push in both tabs of the retainer. 2. Pull the female fitting away from the male fitting. 3. Remove and discard the retainer fitting from the male fitting. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > System Information > Technical Service Bulletins > EVAP System - Service of Connectors > Page 2317 4. Remove and discard the indicator ring (factory use only) from the male fitting. 5. Install a NEW retainer fitting into the female fitting. 6. Connect the fittings together until a snap is heard and/or felt signifying the retainer tabs have engaged the raised feature of the male fitting. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > System Information > Technical Service Bulletins > EVAP System - Service of Connectors > Page 2318 7. Gently pull back on the fittings to verify proper connection of the fittings. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > System Information > Technical Service Bulletins > Page 2319 Evaporative Emissions System: Description and Operation Evaporative Emissions Control System Schematic SYSTEM DESCRIPTION The Evaporative Emission Control System (EECS) uses the basic charcoal canister storage method. This method transfers fuel vapor from the fuel tank to an activated carbon storage canister. This retains the fuel vapors when the vehicle is not operating. When the engine is running, the fuel vapor is purged from the carbon element by intake air flow, and consumed in the normal combustion process. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > System Information > Technical Service Bulletins > Page 2320 Fuel Vapor Canister VAPOR CANISTER AND PURGE OPERATION This evaporative system uses a two tube canister. The fuel vapors vent from the fuel tank to the tube labeled "TANK" on the vapor canister. The canister purge is controlled by a ported vacuum source. The vapors are purged when the engine is running above base idle speed. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > System Information > System Diagnosis > Maintenance Procedures Evaporative Emissions System: Testing and Inspection Maintenance Procedures EGR VALVE INSPECTION AND CLEANING CAUTION: If EGR passages in the intake manifold indicate excessive build-up of carbon deposits, the passages should be cleaned. Care should be taken to ensure that all loose particles are completely removed to prevent them from clogging the EGR valve, or from being ingested into the engine. Do not use chemicals or solvents to clean the EGR valve or intake manifold passages since chemicals may cause damage to the system. Wear approved eye protection for this cleaning procedure, to avoid possible injury to the eyes. Clean the EGR valve as follows: 1. Disconnect the vacuum hose from the EGR valve. Remove the EGR valve-to-manifold retaining bolts, and the control valve. 2. Carefully plug the EGR ports into the intake manifold with a clean shop towel or other suitable cloth. This will prevent debris from falling into the intake port. NOTE: Be sure to remove the cloth from the EGR port before installing the valve. Use compressed air to remove small debris. 3. With a wire wheel, remove the exhaust deposits from the mounting surface of the EGR valve and around the valve. 4. Look for exhaust deposits in the valve outlet, remove deposits as needed. 5. Clean intake manifold mounting surface. 6. Install valve assembly using new gasket, and reconnect the vacuum hose. EGR INTAKE PASSAGE CLEANING When cleaning the intake manifold EGR passages, care should be taken to ensure that all loose particles are completely removed to prevent them from clogging the EGR valve, or from being ingested into the engine. 1. Disconnect the vacuum hose from the EGR valve. Remove the EGR valve-to-manifold retaining bolts, and the control valve (if applicable). 2. Remove the carbon deposits from EGR ports by hand using a suitable sharp tool. 3. Using compressed air, blow the EGR ports clean. Solvents should not be used to clean EGR valve or passages, since damage to the system may result. 4. Install EGR valve, using a new gasket, and reconnect the vacuum hose. EVAPORTIVE CANISTER FILTER REPLACEMENT Check the filter at the bottom of the vapor canister. If the filter is dirty, plugged, or damaged follow the proceeding instructions: 1. Remove all hoses from the top of the canister and mark, then remove the canister. 2. Remove the filter element by squeezing it out from under the lip surface at bottom of canister, and from under the retainer bar, where used. 3. Squeeze the new element under retainer bar, where used, and position it evenly around the entire bottom of the canister. Tuck the edges under the lip of canister. 4. Reinstall the canister to its original position on the vehicle. 5. Reconnect the hoses to the top of the canister, according to the labeling on top of canister. See VACUUM AND VAPOR HOSE DIAGRAMS for proper hose routing. MAINTENANCE SCHEDULES First 6,000 miles (10,000 km) Throttle Body Bolt Mount Torque (see MECHANICAL SPECIFICATIONS)..................................................................................................Check Every 30,000 miles (50,000 km) Fuel Tank, Cap & Lines........................................................................................................................ .................................................................Inspect PCV Valve............................................................... ..............................................................................................................................................Inspect Spark Plugs.......................................................................................................................................... .................................................................Replace Spark Plug Wires................................................... ................................................................................................................................................Inspect Every 30,000 miles (50,000 km) or 24 months Engine Accessory Drive Belt(s)............................................................................................................ .................................................................Inspect Cooling System....................................................... ..................................................................................................................................Service/Inspect Every 30,000 miles (50,000 km) or 36 months EGR System......................................................................................................................................... ..................................................................Inspect Engine Air & PCV Filters........................................ ............................................................................................................................................Replace Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > System Information > System Diagnosis > Maintenance Procedures > Page 2323 Evaporative Emissions System: Testing and Inspection System Diagnosis - Evaporative Emission Controls (EEC) INCORRECT OPERATION MAY CAUSE: 1. Poor idle, stalling, and poor driveability. Check for: a. Damaged canister. b. Hoses split, cracked, or not connected to the proper tubes. c. Pinched or plugged hose(s). 2. Evidence of fuel loss or fuel vapor odor. Check for: a. Liquid fuel leaking from fuel lines, or TBI unit. b. Cracked or damaged canister. c. Disconnected, misrouted, kinked, deteriorated, or damaged vapor hoses. d. Air cleaner or air cleaner gasket improperly seated. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications EGR Valve Bolts 11-18 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 2328 EGR Valve: Locations LH Rear Of Engine, Behind Throttle Body Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation Positive Crankcase Ventilation: Description and Operation PCV Flow SYSTEM DESCRIPTION The PCV system prevents blow-by gases from escaping to atmosphere by routing them through a vacuum controlled ventilation valve, into the intake manifold. The blow-by gases combine with the air/fuel mixture and are burned in the combustion chamber. When the engine is running, fresh air is drawn into the crankcase through a tube or hose connected to the air cleaner housing. The PCV valve, consists of a needle valve, spring and housing. When the engine is off, the spring holds the needle valve closed to stop vapors from entering the intake manifold. When the engine is running, manifold vacuum lifts the valve off its seat and allows crankcase vapors to enter the intake manifold. To maintain idle quality, the PCV valve restricts the flow when the intake manifold vacuum is high. In case of an engine backfire, in the intake manifold, the valve closes. This stops the backflow of gases and prevents the ignition of fuel vapor in the crankcase. During certain engine conditions, more blow-by gases are produced than the PCV valve can handle. In this case, the excess gases are returned through the crankcase vent tube into the air cleaner, where they are burned in the combustion chamber. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 2332 Positive Crankcase Ventilation: Testing and Inspection INCORRECT PCV OPERATION: 1. A plugged PCV valve or hose may cause: a. Rough idle. b. The engine stalls or idle speed decreases. c. Oil in air cleaner. 2. A leaking valve or hose can cause: a. Rough idle. b. Stalling. c. High idle speed. PCV System TEST DESCRIPTION: This test is to see if the PCV System is functioning properly. 1. Check for a correct PCV valve and a properly mounted valve into the rubber gromment. Make sure the hose(s) and clamp(s) are tight, and in place. 2. Start the engine, and let idle. 3. Remove PCV valve from valve cover, and place thumb over valve. 4. Engine speed should drop, and vacuum should be felt. 5. If no vacuum is present, check for a clogged PCV valve, hose, or intake manifold port. 6. Turn the engine off, and remove the PCV valve from hose. Shake the PCV valve and listen for a rattle. If a rattle was not heard, replace the valve. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure, Engine Running ......................................................................................................................................................... 62-90 kPa (9-13 P.S.I.) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2337 Fuel Pressure: Testing and Inspection Fuel System Schematic WARNING: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before connecting a fuel pressure test. Refer to Fuel Pressure Release Procedure. CAUTION To reduce the risk of fire and personal injury: 1. It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge. 2. A small amount of fuel may be released when disconnecting the fuel lines. Cover the fuel lines with a shop towel to catch any fuel leaking out. Place the towel in an approved container once the lines are disconnected. 3. DO NOT pinch or restrict nylon fuel lines to avoid severing. If nylon fuel lines become kinked, and cannot be straightened, they must be replaced. 4. Wear safety glasses at all times. FUEL PRESSURE TESTING 1. Loosen fuel filler cap to relieve fuel tank pressure. (DO NOT tighten at this time.) 2. Raise the vehicle to disconnect the fuel pump electrical connector, then lower the vehicle. 3. Start and run the engine until the residual fuel is consumed. Engage starter for three seconds to assure fuel pressure relief. 4. Disconnect the negative battery cable, and locate the fuel feed pressure line. 5. Connect fuel pressure gage, J-29658-B, in between the fuel feed line and the TBI unit. Use the appropriate adapters. 6. Raise the vehicle to connect the fuel pump electrical connector, then lower the vehicle. 7. Connect the negative battery terminal. 8. Perform fuel pressure checks. 9. Relieve the fuel system pressure. See steps 2 and 3. 10. Disconnect the negative battery terminal and remove fuel pressure gauge. 11. Tighten fuel filler cap and connect the negative battery terminal. 12. Cycle the ignition switch twice, waiting ten seconds between cycles. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair WARNING: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing fuel system components. After relieving system pressure, a small amount of fuel may be released when servicing fuel lines or connections. In order to reduce the chance of personal injury, cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when disconnect is completed. When servicing the fuel system use the following precautions: a. Put a "CAUTION FLAMMABLE" sign in the workshop. b. Be sure shop is supplied with an adequate fire extinguisher. c. Be sure to disconnect battery ground cable before any service work is done. d. Use a suitable container to catch any fuel that may leak from the system during service. e. Always relieve fuel system pressure before disconnecting any lines. f. If the key must be turned ON while servicing the fuel system, always disconnect or disable the ignition, to insure no sparks occur near fuel vapors. g. NEVER turn the ignition on while servicing the fuel system unless the electric fuel pump is disabled. PROCEDURE: 1. Loosen fuel filler cap to relieve tank vapor pressure. 2. Raise the vehicle and disconnect fuel pump electrical connector at fuel tank. 3. Lower vehicle. 4. START engine and RUN until fuel supply remaining in fuel pipes is consumed. Engage starter for 3 seconds to relieve the remaining fuel pressure. 5. Perform required tests or repairs. 6. Raise vehicle and reconnect fuel pump electrical connector at fuel tank. 7. START vehicle for 10 seconds. Shut vehicle OFF and check for leaks. 8. Retighten the fuel tank cap. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Vin R, U, G, Minimum Idle Speed Vin R, U, G, Minimum Idle Speed Idle Speed Note: Let engine idle until proper fuel control status is closed loop. Manual Transmission Neutral 600 +/-50 rpm Automatic Transmission Drive 600 +/-50 rpm Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Idle Speed Idle Speed: Adjustments Idle Speed The throttle plate stop screw, or idle speed, is adjusted at the factory and covered with a plug to discourage unnecessary adjustment. But, if access to the throttle stop screw is necessary, the following procedure eliminates the removal of the Throttle Body unit from the intake manifold. If there is a complaint of high idle speed, vacuum leaks should be considered the most likely cause. The Electronic Control Module (ECM) controls the Idle Air Control (IAC) valve, and it is less likely that a stalling complaint would be due to incorrect idle speed. If either occurs see DIAGNOSIS BY SYMPTOM. If the Minimum Air Rate is suspected, be sure the Idle Air Control (IAC) valve is not "lost" (not actually at the location indicated by current IAC "counts"). The IAC valve could be "lost" if ECM power has been interrupted with the ignition "ON," or the IAC valve has been disconnected with the engine running since the last reset. CAUTION: To prevent engines from running at high speeds, be sure that the ignition is OFF and the vehicle is in PARK or NEUTRAL before connecting Idle Air Control (IAC) assembly, or installing/removing idle air passage plugs. Failure to do this may result in vehicle movement, which can result in personal and/or property damage. Stop Screw Plug Removal The Idle Speed may be checked using the following procedure: 1. Block drive wheels and apply parking brake. 2. Remove the air cleaner housing, and plug the Thermac vacuum port (if applicable). 3. Remove the idle stop screw plug with an awl. 4. Start the engine and allow it to reach operating temperature. 5. Connect a tachometer to the engine. 6. With Idle Air Control (IAC) valve connected, jump terminals A and B of the ALDL connector to ground the diagnostic terminal. See ON-BOARD DIAGNOSTIC CHECK for ALDL diagram. 7. Turn the ignition ON, but do not start the engine. Wait at least 45 seconds to allow the IAC pintle time to bottom in its seat. This closes the air passage in the TBI unit. 8. With the ignition ON, engine not running and diagnostic lead grounded, disconnect the IAC valve electrical connector. 9. Remove the ground from the diagnostic connector, and start the engine. Allow the engine speed to stabilize. 10. Adjust the idle stop screw. See MECHANICAL SPECIFICATIONS for idle speed specifications. 11. Turn OFF the ignition and reconnect the IAC electrical connector. 12. Reset the IAC valve by starting the engine and allowing it to run at 2000 rpm for ten seconds. Then turn OFF the ignition switch. 13. Cover the idle stop screw with silicone or similar sealant. 14. Remove the test instruments and reinstall the air cleaner housing. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Idle Speed > Page 2346 Idle Speed: Adjustments Minimum Air Rate - Fuel Injection Only NOTE: The minimum idle air rate is set at the factory with a stop screw and is not normally readjusted unless repairs or replacement of the throttle body assembly has occurred. Engine idle speed is computer controlled through the IAC valve and is not adjustable. If there is a complaint of high idle speed, vacuum leaks should be considered the most likely cause. The Electronic Control Module (ECM) controls the Idle Air Control (IAC) valve, and it is less likely that a stalling complaint would be due to incorrect minimum idle speed. If either occurs, refer to Diagnosis by Symptom. If the Minimum Air Rate is suspected, be sure the Idle Air Control (IAC) valve is not "lost" (not actually at the location indicated by current IAC "counts"). The IAC valve could be "lost" if ECM power has been interrupted with the ignition "ON," or the IAC valve has been disconnected with the engine running since the last reset. CAUTION: To prevent engines from running at high speeds, be sure that the ignition is OFF and the vehicle is in PARK or NEUTRAL before connecting Idle Air Control (IAC) assembly, or installing/removing idle air passage plugs. Failure to do this may result in vehicle movement, which can result in personal and/or property damage. MINIMUM IDLE AIR RATE CHECK 1. START engine and bring it to normal operating temperatures 185-212 degrees Fahrenheit (85-100 degrees Celsius). Turn engine OFF. 2. Remove air cleaner assembly. Remove hoses and plug any possible air sources on tube manifold assembly. 3. Disconnect throttle cable. 4. Ground diagnostic "test" terminal in ALDL connector. (jumper A to B) 5. Turn ON ignition, DO NOT START engine. Wait at least 10 seconds (this will allow the IAC pintle to extend and seat in the throttle body). 6. With ignition ON, engine stopped, test terminal still grounded, disconnect IAC valve electrical connector. (This disables the IAC valve in the seated position). Remove the ground from the diagnostic terminal. 7. Connect a scan tool to the ALDL connector and place in open mode. If a tool is not available connect a tachometer to the engine. 8. START engine. With transmission in NEUTRAL, allow engine rpm to stabilize. It may be necessary to depress the accelerator in order to start the engine. 9. Idle speed should be 550 to 650 RPM. Adjust idle stop screw if necessary. To remove the soft plug, puncture with an awl and pry out. Stop Screw Plug Removal 10. If the minimum idle air rate is within 550 to 650 RPM, no further check is required. 11. Turn ignition OFF and reconnect IAC valve electrical connector. 12. Disconnect the SCAN tool or tachometer. 13. The IAC valve will be reset by the computer when the vehicle speed exceeds 43 MPH while the engine speed is above 2000 RPM or when the diagnostic test connector is grounded when the engine RPM is above 2000 RPM. 14. Install air cleaner, adapter, gasket and vacuum hoses. NOTE: The minimum idle air rate is set at the factory with a stop screw, which is covered with a tamper plug. This setting allows enough air flow by the Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Idle Speed > Page 2347 throttle valves to cause the IAC valve pintle to be positioned a calibrated number of steps (counts), from the seat, during "controlled" idle operation. If the IAC valve is disconnected and reconnected with the engine running, the idle speed may be wrong. In this case, the IAC valve can be reset by doing the following: The IAC valve will be reset by the computer when the vehicle speed exceeds 43 MPH while the engine speed is above 2000 RPM or when the diagnostic test connector is grounded when the engine RPM is above 2000 RPM. Engine idle speed is computer controlled through the IAC valve, by driving the IAC pintle in and out. Engine idle speed is a funtion of total air flow into the engine based on: IAC valve position, throttle valve opening (idle stop screw), calibrated leakage through the accessories, PCV flow. "Controlled" idle speed is programed into the ECM, which determines the correct IAC valve pintle position to maintain the desired idle speed. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Controls <--> [Accelerator Pedal] > Component Information > Locations Accelerator Controls: Locations Accelerator Controls - Engine Compartment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Controls <--> [Accelerator Pedal] > Component Information > Locations > Page 2351 Accelerator Controls - Passenger Compartment Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Controls <--> [Accelerator Pedal] > Component Information > Locations > Page 2352 Accelerator Controls: Service and Repair Accelerator Controls - Passenger Compartment Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Controls <--> [Accelerator Pedal] > Component Information > Locations > Page 2353 Accelerator Controls - Engine Compartment. ACCELERATOR PEDAL: When performing service on the accelerator pedal, observe the following: ^ The braided portion of the accelerator cable assembly must not come in contact with the front of the dash sealer during assembly, repair, or replacement of the assembly. ^ The mounting surface between the support and dash panel must be free of insulation. The carpet and padding in the pedal and tunnel area must be positioned to lay flat and be free on wrinkles and bunches. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Controls <--> [Accelerator Pedal] > Component Information > Locations > Page 2354 ^ Slip the accelerator control cable through the slot in the rod and then install the retainer in the rod, makeing sure it is seated. Use care when pressing the retainer into the hole in the rod to ensure that the cable is not kinked or damaged in any way. ^ After securing all components of the accelerator linkage, the linkage must operate freely without binding between full closed throttle and full wide open throttle. ^ Wires, hoses, cables or other obstructions must not be placed within 13 mm (1/2 inch) of the cable or the rod at any point in their travel. ACCELERATOR CONTROL CABLE: When performing service on the accelerator control cable, observe the following: ^ The retainer must be installed with the tangs secured overhead of the stud. ^ The conduit fitting at both ends of the cable must have the locking tangs expanded and locked in the attaching holes. ^ The flexible components (hoses, wires, conduits, etc.) must be routed within 50 mm (2 inches) of the moving parts of the accelerator linkage outboard of the support unless the routing is positively controlled. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2364 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > 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 2370 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Customer Interest: > 93966C > Feb > 93 > Fuel System - Factors That Affect Economy/Mileage Fuel: Customer Interest Fuel System - Factors That Affect Economy/Mileage Number: 93-96-6C Section: 6C Date: FEB. 1993 Corporate Bulletin No.: 306502 ASE No.: A1, A8 Subject: FACTORS THAT AFFECT FUEL ECONOMY Model and Year: ALL YEARS ALL MODELS BACKGROUND INFORMATION: EPA fuel economy estimates are posted on the fuel economy label of all new vehicles. The only intended use of these values is for comparison among the different vehicles. Fuel economy estimates are generated from data taken during a laboratory test using pre-production prototype vehicles under extremely controlled conditions using a professional driver, with the vehicle operating on an instrument similar to a treadmill. The comparisons of current vehicle fuel economy to the EPA fuel economy estimates is a misuse of the information and should be discouraged. The EPA GAS MILEAGE GUIDE, available at each dealership, points out that the actual mileage when driving a vehicle may differ considerably from the estimated mileage. The guide also describes how vehicles are tested under identical conditions to insure the results can be compared with confidence. The EPA GAS MILEAGE GUIDE also points out that city fuel economy estimate simulates a 7.5 mile, stop-and-go trip with an average speed of 20 mph. The trip takes 23 minutes and has 18 stops. About 18 percent of the time is spent idling, as in waiting at traffic lights or in rush hour traffic. Two kinds of engine starts are used - the cold start, which is similar to starting a car in the morning after it has been parked all night - and the hot start, similar to restarting a vehicle after it has been warmed up, driven and stopped for a short time. The test to determine the highway fuel economy estimate represents a mixture of "non-city" driving. Segments corresponding to different kinds of rural roads and interstate highways are included. The test simulates a 10 mile trip and averages 48 mph. The test is run from a hot start and has little idling time and no stops. The EPA GAS MILEAGE GUIDE explains that the actual test results are adjusted downward to arrive at the estimates used in the booklet and on the labels. City estimates are lowered by 10 percent and the highway estimate by 22 percent from the laboratory test results. The guide also points out that traveling at higher speeds lowers fuel economy and traveling at 65 mph instead of 55 mph lowers fuel economy over 15 percent. FACTORS THAT AFFECT FUEL ECONOMY: Axle Ratio Numerically lower axle ratios generally produce better highway fuel economy. The exception to this is if the engine is "working" exceptionally hard, (heavy vehicle loads pulling a trailer, small engine in a large vehicle ... ). In these cases a numerically higher axle may provide better fuel economy. Numerically higher axle ratios will also tend to provide more fuel economy in congested city traffic and stop and go conditions. Brakes Brake drag (even a minimal amount undetectable by coasting), can have a significant negative impact on fuel economy. Pull upward on the brake pedal to assure that the stoplight switch and cruise switch at the brake pedal are full and properly adjusted. A "click" sound when the pedal is pulled upward indicates that the switch was improperly adjusted. This causes the front brake pads to lightly rub the rotors, causing a fuel economy loss, without generating excessive heat or brake pad wear. Driving Habits Frequent short trips (less than 5 miles), especially in cooler ambient temperatures (less than 65 degrees), will necessitate fuel enrichment on start-ups, especially after "soaks" with the engine off for approximately a half hour or more. Frequent accelerator pedal movement while driving will reduce fuel economy because of fuel enrichment during the periods of acceleration. Under such driving conditions the torque converter clutch (TCC) also disengages, contributing to fuel economy losses. Prolonged idle periods reduce fuel economy especially in cold ambients when vehicle is allowed to "Warm up". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Customer Interest: > 93966C > Feb > 93 > Fuel System - Factors That Affect Economy/Mileage > Page 2379 Fuels Oxygenated fuels, with methanol and/or ethanol blended into the gasoline have lower energy and thus reduce fuel economy. Typically there is about a 1 MPG penalty for a vehicle which gets 25 to 30 MPG on 100 percent gasoline. Using fuels of a lower octane than the vehicle was calibrated to will cause increased "KS" Knock Sensor system activity. This will result in a net decrease in spark advance and thus poorer fuel economy. Using fuel of a higher octane than the vehicle was calibrated for WILL NOT increase fuel economy. Variations in how much fuel is added to the fuel tank during re-fueling can greatly affect calculated fuel economy. These effects decrease as the distance traveled and the number of tank fillups increase. Green Engine New vehicles have not yet had an opportunity for the engine to break in, (rings to seat ... ). A typical engine will take 3 to 5 thousand miles to break in and during this time period a gradual increase in fuel economy can be expected. Parasitic Loads Air conditioning and/or electrical loads, (headlights, heated backglass ... ) also result in lower fuel economy, (typically less than 1 MPG difference, each 10 AMPs takes approximately .4 MPG). Road Conditions Road surface condition impacts fuel economy. Gravel and/or pot holed roads decrease fuel economy. Hills (vs. level terrain) also negatively impact fuel economy. Even gradual unperceptible increases in elevation result in real measurable decreases in fuel economy. Similarly, driving in the rain or snow decreases fuel economy. Suspension Vehicle suspension misalignment can cause poor fuel economy. Check all four tires for abnormal and/or premature tire wear. New tires, tire rotation, and/or front end alignment may be required to correct fuel economy. Tires Performance tires and/or tires with larger "contact areas," (like 60 series aspect ratio), can cause as much as 3 MPG lower fuel economy when compared to hard "thin" tires. Find out if the tire size currently on the car is the same as original equipment. Replacement tires tailor than original equipment tires cause the odometer to read LESS THAN actual distance traveled. This will result in lower calculated fuel economy than actual fuel economy. Tire Pressure Harder tires, (more air pressure, or different tire compositions) result in better fuel economy. Do not exceed maximum pressure as labeled on the tire, typically 30-35 psi. The disadvantage of this is that the greater the tire pressure, the harsher the vehicle ride. Transmission On 4-Speed automatics, it is possible to drive the vehicle in 3rd gear rather than "overdrive" and not perceive it. Typically this condition occurs when the shift indicator, or the shift linkage/detent is misadjusted. Misadjusted shift linkage can also result in improper signals to the ECM, which can result in less spark advance, and results in a drop in fuel economy. Driving a vehicle in 3rd gear rather than overdrive at highway speeds typically results in a 3 to 5 MPG penalty. Torque Converter Clutch operation is essential for good fuel economy. A non-locking torque converter typically results in a 1 to 2 MPG penalty at highway speeds. Vehicle Weight Each 125 lbs. of additional weight results in a .3 MPG loss of fuel economy. Thus, additional passengers, luggage ... will decrease fuel economy. Vehicle Wind Resistance More wind "DRAG" means less fuel economy. Thus, hang-on luggage carders, cat toppers, open windows and/or open trunk... mean less fuel economy. (See "Driving Habits"). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Customer Interest: > 93316C > Oct > 92 > Fuels - Effect of Volatility on Driveability Fuel: Customer Interest Fuels - Effect of Volatility on Driveability Number: 93-31-6C Section: 6C Date: OCT. 1992 Corporate Bulletin No.: 249128R ASE No.: A1, A8 Subject: EFFECT OF FUEL VOLATILITY ON DRIVEABILITY CONDITIONS Model and Year: ALL MODEL YEARS, ALL PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 92-281-6C, DATED SEPT. 1992. THE 1993 MODEL YEAR HAS BEEN ADDED. ALL COPIES OF 92-281-6C SHOULD BE DISCARDED. Recent changes in EPA regulations have effectively lowered the maximum allowable fuel volatility. Volatility, which can be defined as a gasoline's ability to change from a liquid to a vapor, directly affects the amount of evaporative emissions produced by the fuel. Higher volatility means that more unburned hydrocarbons will be released into the atmosphere. Unfortunately, reducing fuel volatility can cause problems during cold engine operation when low temperatures impede the fuel's ability to vaporize and burn. Two terms are often used to describe volatility characteristics. These are: Distillation Curve A graph showing the relationship between temperature and the percentage of fuel evaporated. The fuel components that boil at relatively low temperatures (below about 90 degrees F) are known as the "light ends", and are essential for good cold engine performance. The "heavy ends", which begin to boil at about 300 degrees F, contain the most energy but are more difficult to burn. Laboratory analysis is usually required to determine the distillation curve of a gasoline sample. - Reid Vapor Pressure (RVP) RVP is the pressure (psi) that vaporized fuel exerts within a sealed container as it is heated to 100 degrees F. The higher the RVP the higher the fuel volatility. While RVP is readily tested in the field, fuels of the same RVP can have different distillation curves and cold driveability characteristics. Fuel volatility will vary depending on geographic location and time of year (fuel intended to be used in higher ambient conditions is formulated with less volatility). This can make cold driveability as big a problem during summer months as during the winter. There may be additional variation in the volatility characteristics of pump gasoline, caused by the differences in fuel manufacturers, blends and storage times. As EPA fuel volatility standards are lowered, variations between fuels (which may further reduce volatility) becomes a critical factor influencing cold engine performance. No matter how thoroughly the relationship between fuel quality and cold driveability is understood, eliminating fuel quality as an issue can be difficult, because: TOOLS WHICH TEST FUEL VOLATILITY MEASURE ONLY RVP, NOT THE DISTILLATION CURVE. The distillation curve has a greater effect on cold driveability than RVP. THE CUSTOMER MAY PERCEIVE RAISING THE FUEL QUALITY ISSUE AS AN ATTEMPT TO EVADE HIS PROBLEM. This may cause difficulty in getting accurate fuel usage information. WATER, AND OTHER TYPES OF FUEL CONTAMINATION, MAY CAUSE CONTINUED DRIVEABILITY COMPLAINTS. - The problem symptoms may remain even though the vehicle has been refueled several times with a quality gasoline. CUSTOMER CONCERNS CONDITION: Poor Cold Engine Operation, symptoms may include; hard start/extended crank, stalling, backfiring, hesitation and/or lack of power. POSSIBLE CAUSE: Low volatility fuel will not vaporize sufficiently to allow normal combustion. CORRECTION: Replace Fuel. DIAGNOSTIC PROCEDURE: 1. Perform basic system checks in section 6E of the service manual. 2. Check for service bulletins which relate to cold driveability issues specific to the problem vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Customer Interest: > 93316C > Oct > 92 > Fuels - Effect of Volatility on Driveability > Page 2384 - An updated engine control calibration, or service procedure, may be available to make the engine less susceptible to low volatility fuels. 3. If basic checks do not reveal a vehicle fault, then advise the customer that fuel quality may be an issue. Recommend the following actions: Change brands of fuel - Use 87 octane gasoline, unless the vehicle is designed for premium gasoline. - Try to empty the fuel tank as much as practical before refilling. - Run a minimum of three tanks of new fuel before returning for service. 4. If above steps are ineffective, do not proceed with additional vehicle diagnosis and/or parts replacement until the fuel tank has been drained and refilled with a known good quality gasoline AT THE DEALERSHIP. 5. If the problem remains refer to service manual, service bulletins and/or technical assistance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Customer Interest: > 912226E > Mar > 91 > Engine - Cold Acceleration Hesitation or Stall Fuel: Customer Interest Engine - Cold Acceleration Hesitation or Stall Number: 91-222-6E Section: 6E Date: March 1991 Corporate Bulletin No.: 136502 Subject: HESITATION OR STALL ON COLD ACCELERATION Model and Year: 1990-91 CAVALIER, CORSICA, BERETTA WITH 2.2L ENGINE AND 3T40 AUTOMATIC TRANSMISSION Condition: Some owners of 1990 and 1991 J and L cars with 2.2L engines may comment of an engine hesitation or stall during a cold acceleration. Cause: Low volatility fuel that does not fully vaporize in a cold intake manifold. Correction: New PROM packages have been released which compensate for low volatility fuel during cold acceleration. Install the correct PROM package based on the chart below, and recommend that the owner use low octane fuel (87 or equivalent). Vehicles Affected: Body Model Emissions Assembly Vehicles Style Year Type Plant Affected J 1990 Federal Janesville All Lordstown All Calif. Janesville All Lordstown All 1991 Federal Janesville All Lordstown VIN Prior to M7173516 Calif. Janesville ALL Lordstown VIN Prior to M7173032 L 1990 Federal Linden All Wilmington All Calif. Linden All Wilmington All 1991 Federal Linden VIN Prior to ME1 42136 Wilmington VIN Prior to MY159347 Calif. Linden VIN Prior to ME142841 Wilmington VIN Prior to MY159089 PROM Applications: Body Emissions Broadcast Scanner PROM Part Style Type Code I.D. Number J Federal AWWM 8321 16158344 Calif. AWWN 8331 16158349 L Federal AWWP 8341 16158354 Calif. AWWR 8351 16158358 Parts are currehtly available from GMSPO. Labor Operation Number: T0500 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Customer Interest: > 912226E > Mar > 91 > Engine - Cold Acceleration Hesitation or Stall > Page 2389 Labor Hours: 0.4 Hours Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 05-06-04-022G > Oct > 10 > Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 05-06-04-022G > Oct > 10 > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 2395 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 05-06-04-022G > Oct > 10 > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 2396 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 04-06-04-047I > Aug > 09 > Fuel System - 'TOP TIER' Detergent Gasoline Information Fuel: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 04-06-04-047I > Aug > 09 > Fuel System - 'TOP TIER' Detergent Gasoline Information > Page 2401 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 570102 > Jun > 95 > Fuel Reformulated/Oxygenated Gasolines Fuel: All Technical Service Bulletins Fuel - Reformulated/Oxygenated Gasolines FILE IN SECTION: 0 - General Information BULLETIN NO.: 57-01-02 DATE: June, 1995 SUBJECT: Reformulated Gasoline (RFG), Oxygenated Gasoline and California Phase 2 RFG MODELS: 1995 and Prior Passenger Cars and Trucks General Motors customers will be potentially exposed to a variety of different fuel types. Besides the conventional gasoline available, new types such as Reformulated Gasoline (RFG), oxygenated gasoline, and starting in 1996, California Phase 2 RFG. Reformulated Gasoline (RFG) is blended to burn more cleanly and not to evaporate as readily. RFG must contain a minimum of 2 percent oxygen, which is usually achieved with ethanol or EPA-approved ethers such as methyl tertiary-butyl ether (MTBE). This type of fuel is required by the Clean Air Act in the nine worst ozone non-attainment areas of the country, and may also be required in other areas designated ozone non-attainment, at the option of the states. RFG is intended to produce approximately 15 percent less pollution than conventional gasoline. Using RFG should reduce the total health risk to the public by reducing exposure to ozone and air toxins. General Motors supports the use of RFG as a cost effective means of providing air quality benefits. Oxygenated gasolines are prevalent in the wintertime for Carbon Monoxide (CO) non-attainment areas. These fuels contain oxygen components similar to RFG. Approximately 50 percent of the fuel sold in the U.S. in the wintertime contains an oxygenate component. Vehicle fuel economy may be slightly reduced, if at all, by the use of gasoline containing oxygenates. Fuel economy is most affected by engine and vehicle type, driving habits, weather conditions, and vehicle maintenance. Properly blended RFG, oxygenated gasoline, and California Phase 2 RFG will have no adverse effect on vehicle performance or to the durability of engine and fuel system components. In fact, the General Motors Owner's Manual fuel statements have consistently permitted the use of properly blended fuels containing up to 10 percent ethanol (since 1980) and up to 15 percent methyl tertiary-butyl ether (MTBE) for current and all past model year vehicles. These statements continue to be valid. The use of oxygenate-containing fuels will not invalidate the GM vehicle warranty. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 93966C > Feb > 93 > Fuel System - Factors That Affect Economy/Mileage Fuel: All Technical Service Bulletins Fuel System - Factors That Affect Economy/Mileage Number: 93-96-6C Section: 6C Date: FEB. 1993 Corporate Bulletin No.: 306502 ASE No.: A1, A8 Subject: FACTORS THAT AFFECT FUEL ECONOMY Model and Year: ALL YEARS ALL MODELS BACKGROUND INFORMATION: EPA fuel economy estimates are posted on the fuel economy label of all new vehicles. The only intended use of these values is for comparison among the different vehicles. Fuel economy estimates are generated from data taken during a laboratory test using pre-production prototype vehicles under extremely controlled conditions using a professional driver, with the vehicle operating on an instrument similar to a treadmill. The comparisons of current vehicle fuel economy to the EPA fuel economy estimates is a misuse of the information and should be discouraged. The EPA GAS MILEAGE GUIDE, available at each dealership, points out that the actual mileage when driving a vehicle may differ considerably from the estimated mileage. The guide also describes how vehicles are tested under identical conditions to insure the results can be compared with confidence. The EPA GAS MILEAGE GUIDE also points out that city fuel economy estimate simulates a 7.5 mile, stop-and-go trip with an average speed of 20 mph. The trip takes 23 minutes and has 18 stops. About 18 percent of the time is spent idling, as in waiting at traffic lights or in rush hour traffic. Two kinds of engine starts are used - the cold start, which is similar to starting a car in the morning after it has been parked all night - and the hot start, similar to restarting a vehicle after it has been warmed up, driven and stopped for a short time. The test to determine the highway fuel economy estimate represents a mixture of "non-city" driving. Segments corresponding to different kinds of rural roads and interstate highways are included. The test simulates a 10 mile trip and averages 48 mph. The test is run from a hot start and has little idling time and no stops. The EPA GAS MILEAGE GUIDE explains that the actual test results are adjusted downward to arrive at the estimates used in the booklet and on the labels. City estimates are lowered by 10 percent and the highway estimate by 22 percent from the laboratory test results. The guide also points out that traveling at higher speeds lowers fuel economy and traveling at 65 mph instead of 55 mph lowers fuel economy over 15 percent. FACTORS THAT AFFECT FUEL ECONOMY: Axle Ratio Numerically lower axle ratios generally produce better highway fuel economy. The exception to this is if the engine is "working" exceptionally hard, (heavy vehicle loads pulling a trailer, small engine in a large vehicle ... ). In these cases a numerically higher axle may provide better fuel economy. Numerically higher axle ratios will also tend to provide more fuel economy in congested city traffic and stop and go conditions. Brakes Brake drag (even a minimal amount undetectable by coasting), can have a significant negative impact on fuel economy. Pull upward on the brake pedal to assure that the stoplight switch and cruise switch at the brake pedal are full and properly adjusted. A "click" sound when the pedal is pulled upward indicates that the switch was improperly adjusted. This causes the front brake pads to lightly rub the rotors, causing a fuel economy loss, without generating excessive heat or brake pad wear. Driving Habits Frequent short trips (less than 5 miles), especially in cooler ambient temperatures (less than 65 degrees), will necessitate fuel enrichment on start-ups, especially after "soaks" with the engine off for approximately a half hour or more. Frequent accelerator pedal movement while driving will reduce fuel economy because of fuel enrichment during the periods of acceleration. Under such driving conditions the torque converter clutch (TCC) also disengages, contributing to fuel economy losses. Prolonged idle periods reduce fuel economy especially in cold ambients when vehicle is allowed to "Warm up". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 93966C > Feb > 93 > Fuel System - Factors That Affect Economy/Mileage > Page 2410 Fuels Oxygenated fuels, with methanol and/or ethanol blended into the gasoline have lower energy and thus reduce fuel economy. Typically there is about a 1 MPG penalty for a vehicle which gets 25 to 30 MPG on 100 percent gasoline. Using fuels of a lower octane than the vehicle was calibrated to will cause increased "KS" Knock Sensor system activity. This will result in a net decrease in spark advance and thus poorer fuel economy. Using fuel of a higher octane than the vehicle was calibrated for WILL NOT increase fuel economy. Variations in how much fuel is added to the fuel tank during re-fueling can greatly affect calculated fuel economy. These effects decrease as the distance traveled and the number of tank fillups increase. Green Engine New vehicles have not yet had an opportunity for the engine to break in, (rings to seat ... ). A typical engine will take 3 to 5 thousand miles to break in and during this time period a gradual increase in fuel economy can be expected. Parasitic Loads Air conditioning and/or electrical loads, (headlights, heated backglass ... ) also result in lower fuel economy, (typically less than 1 MPG difference, each 10 AMPs takes approximately .4 MPG). Road Conditions Road surface condition impacts fuel economy. Gravel and/or pot holed roads decrease fuel economy. Hills (vs. level terrain) also negatively impact fuel economy. Even gradual unperceptible increases in elevation result in real measurable decreases in fuel economy. Similarly, driving in the rain or snow decreases fuel economy. Suspension Vehicle suspension misalignment can cause poor fuel economy. Check all four tires for abnormal and/or premature tire wear. New tires, tire rotation, and/or front end alignment may be required to correct fuel economy. Tires Performance tires and/or tires with larger "contact areas," (like 60 series aspect ratio), can cause as much as 3 MPG lower fuel economy when compared to hard "thin" tires. Find out if the tire size currently on the car is the same as original equipment. Replacement tires tailor than original equipment tires cause the odometer to read LESS THAN actual distance traveled. This will result in lower calculated fuel economy than actual fuel economy. Tire Pressure Harder tires, (more air pressure, or different tire compositions) result in better fuel economy. Do not exceed maximum pressure as labeled on the tire, typically 30-35 psi. The disadvantage of this is that the greater the tire pressure, the harsher the vehicle ride. Transmission On 4-Speed automatics, it is possible to drive the vehicle in 3rd gear rather than "overdrive" and not perceive it. Typically this condition occurs when the shift indicator, or the shift linkage/detent is misadjusted. Misadjusted shift linkage can also result in improper signals to the ECM, which can result in less spark advance, and results in a drop in fuel economy. Driving a vehicle in 3rd gear rather than overdrive at highway speeds typically results in a 3 to 5 MPG penalty. Torque Converter Clutch operation is essential for good fuel economy. A non-locking torque converter typically results in a 1 to 2 MPG penalty at highway speeds. Vehicle Weight Each 125 lbs. of additional weight results in a .3 MPG loss of fuel economy. Thus, additional passengers, luggage ... will decrease fuel economy. Vehicle Wind Resistance More wind "DRAG" means less fuel economy. Thus, hang-on luggage carders, cat toppers, open windows and/or open trunk... mean less fuel economy. (See "Driving Habits"). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 93316C > Oct > 92 > Fuels - Effect of Volatility on Driveability Fuel: All Technical Service Bulletins Fuels - Effect of Volatility on Driveability Number: 93-31-6C Section: 6C Date: OCT. 1992 Corporate Bulletin No.: 249128R ASE No.: A1, A8 Subject: EFFECT OF FUEL VOLATILITY ON DRIVEABILITY CONDITIONS Model and Year: ALL MODEL YEARS, ALL PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 92-281-6C, DATED SEPT. 1992. THE 1993 MODEL YEAR HAS BEEN ADDED. ALL COPIES OF 92-281-6C SHOULD BE DISCARDED. Recent changes in EPA regulations have effectively lowered the maximum allowable fuel volatility. Volatility, which can be defined as a gasoline's ability to change from a liquid to a vapor, directly affects the amount of evaporative emissions produced by the fuel. Higher volatility means that more unburned hydrocarbons will be released into the atmosphere. Unfortunately, reducing fuel volatility can cause problems during cold engine operation when low temperatures impede the fuel's ability to vaporize and burn. Two terms are often used to describe volatility characteristics. These are: Distillation Curve A graph showing the relationship between temperature and the percentage of fuel evaporated. The fuel components that boil at relatively low temperatures (below about 90 degrees F) are known as the "light ends", and are essential for good cold engine performance. The "heavy ends", which begin to boil at about 300 degrees F, contain the most energy but are more difficult to burn. Laboratory analysis is usually required to determine the distillation curve of a gasoline sample. - Reid Vapor Pressure (RVP) RVP is the pressure (psi) that vaporized fuel exerts within a sealed container as it is heated to 100 degrees F. The higher the RVP the higher the fuel volatility. While RVP is readily tested in the field, fuels of the same RVP can have different distillation curves and cold driveability characteristics. Fuel volatility will vary depending on geographic location and time of year (fuel intended to be used in higher ambient conditions is formulated with less volatility). This can make cold driveability as big a problem during summer months as during the winter. There may be additional variation in the volatility characteristics of pump gasoline, caused by the differences in fuel manufacturers, blends and storage times. As EPA fuel volatility standards are lowered, variations between fuels (which may further reduce volatility) becomes a critical factor influencing cold engine performance. No matter how thoroughly the relationship between fuel quality and cold driveability is understood, eliminating fuel quality as an issue can be difficult, because: TOOLS WHICH TEST FUEL VOLATILITY MEASURE ONLY RVP, NOT THE DISTILLATION CURVE. The distillation curve has a greater effect on cold driveability than RVP. THE CUSTOMER MAY PERCEIVE RAISING THE FUEL QUALITY ISSUE AS AN ATTEMPT TO EVADE HIS PROBLEM. This may cause difficulty in getting accurate fuel usage information. WATER, AND OTHER TYPES OF FUEL CONTAMINATION, MAY CAUSE CONTINUED DRIVEABILITY COMPLAINTS. - The problem symptoms may remain even though the vehicle has been refueled several times with a quality gasoline. CUSTOMER CONCERNS CONDITION: Poor Cold Engine Operation, symptoms may include; hard start/extended crank, stalling, backfiring, hesitation and/or lack of power. POSSIBLE CAUSE: Low volatility fuel will not vaporize sufficiently to allow normal combustion. CORRECTION: Replace Fuel. DIAGNOSTIC PROCEDURE: 1. Perform basic system checks in section 6E of the service manual. 2. Check for service bulletins which relate to cold driveability issues specific to the problem vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 93316C > Oct > 92 > Fuels - Effect of Volatility on Driveability > Page 2415 - An updated engine control calibration, or service procedure, may be available to make the engine less susceptible to low volatility fuels. 3. If basic checks do not reveal a vehicle fault, then advise the customer that fuel quality may be an issue. Recommend the following actions: Change brands of fuel - Use 87 octane gasoline, unless the vehicle is designed for premium gasoline. - Try to empty the fuel tank as much as practical before refilling. - Run a minimum of three tanks of new fuel before returning for service. 4. If above steps are ineffective, do not proceed with additional vehicle diagnosis and/or parts replacement until the fuel tank has been drained and refilled with a known good quality gasoline AT THE DEALERSHIP. 5. If the problem remains refer to service manual, service bulletins and/or technical assistance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 912226E > Mar > 91 > Engine - Cold Acceleration Hesitation or Stall Fuel: All Technical Service Bulletins Engine - Cold Acceleration Hesitation or Stall Number: 91-222-6E Section: 6E Date: March 1991 Corporate Bulletin No.: 136502 Subject: HESITATION OR STALL ON COLD ACCELERATION Model and Year: 1990-91 CAVALIER, CORSICA, BERETTA WITH 2.2L ENGINE AND 3T40 AUTOMATIC TRANSMISSION Condition: Some owners of 1990 and 1991 J and L cars with 2.2L engines may comment of an engine hesitation or stall during a cold acceleration. Cause: Low volatility fuel that does not fully vaporize in a cold intake manifold. Correction: New PROM packages have been released which compensate for low volatility fuel during cold acceleration. Install the correct PROM package based on the chart below, and recommend that the owner use low octane fuel (87 or equivalent). Vehicles Affected: Body Model Emissions Assembly Vehicles Style Year Type Plant Affected J 1990 Federal Janesville All Lordstown All Calif. Janesville All Lordstown All 1991 Federal Janesville All Lordstown VIN Prior to M7173516 Calif. Janesville ALL Lordstown VIN Prior to M7173032 L 1990 Federal Linden All Wilmington All Calif. Linden All Wilmington All 1991 Federal Linden VIN Prior to ME1 42136 Wilmington VIN Prior to MY159347 Calif. Linden VIN Prior to ME142841 Wilmington VIN Prior to MY159089 PROM Applications: Body Emissions Broadcast Scanner PROM Part Style Type Code I.D. Number J Federal AWWM 8321 16158344 Calif. AWWN 8331 16158349 L Federal AWWP 8341 16158354 Calif. AWWR 8351 16158358 Parts are currehtly available from GMSPO. Labor Operation Number: T0500 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 912226E > Mar > 91 > Engine - Cold Acceleration Hesitation or Stall > Page 2420 Labor Hours: 0.4 Hours Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 05-06-04-022G > Oct > 10 > Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 05-06-04-022G > Oct > 10 > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 2426 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 05-06-04-022G > Oct > 10 > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 2427 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 04-06-04-047I > Aug > 09 > Fuel System - 'TOP TIER' Detergent Gasoline Information Fuel: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 04-06-04-047I > Aug > 09 > Fuel System - 'TOP TIER' Detergent Gasoline Information > Page 2432 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 570102 > Jun > 95 > Fuel - Reformulated/Oxygenated Gasolines Fuel: All Technical Service Bulletins Fuel - Reformulated/Oxygenated Gasolines FILE IN SECTION: 0 - General Information BULLETIN NO.: 57-01-02 DATE: June, 1995 SUBJECT: Reformulated Gasoline (RFG), Oxygenated Gasoline and California Phase 2 RFG MODELS: 1995 and Prior Passenger Cars and Trucks General Motors customers will be potentially exposed to a variety of different fuel types. Besides the conventional gasoline available, new types such as Reformulated Gasoline (RFG), oxygenated gasoline, and starting in 1996, California Phase 2 RFG. Reformulated Gasoline (RFG) is blended to burn more cleanly and not to evaporate as readily. RFG must contain a minimum of 2 percent oxygen, which is usually achieved with ethanol or EPA-approved ethers such as methyl tertiary-butyl ether (MTBE). This type of fuel is required by the Clean Air Act in the nine worst ozone non-attainment areas of the country, and may also be required in other areas designated ozone non-attainment, at the option of the states. RFG is intended to produce approximately 15 percent less pollution than conventional gasoline. Using RFG should reduce the total health risk to the public by reducing exposure to ozone and air toxins. General Motors supports the use of RFG as a cost effective means of providing air quality benefits. Oxygenated gasolines are prevalent in the wintertime for Carbon Monoxide (CO) non-attainment areas. These fuels contain oxygen components similar to RFG. Approximately 50 percent of the fuel sold in the U.S. in the wintertime contains an oxygenate component. Vehicle fuel economy may be slightly reduced, if at all, by the use of gasoline containing oxygenates. Fuel economy is most affected by engine and vehicle type, driving habits, weather conditions, and vehicle maintenance. Properly blended RFG, oxygenated gasoline, and California Phase 2 RFG will have no adverse effect on vehicle performance or to the durability of engine and fuel system components. In fact, the General Motors Owner's Manual fuel statements have consistently permitted the use of properly blended fuels containing up to 10 percent ethanol (since 1980) and up to 15 percent methyl tertiary-butyl ether (MTBE) for current and all past model year vehicles. These statements continue to be valid. The use of oxygenate-containing fuels will not invalidate the GM vehicle warranty. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 2437 Fuel: Specifications ALCOHOL FUEL TYPES Methyl Tertiary-Butyl Ether Fuel containing Methyl Tertiary-butyl Ether (MTBE) may be used, providing there is no more than 15% alcohol by volume. Ethanol Fuel containing ethanol (ethyl) or grain alcohol may be used, providing there is no more than 10% ethanol alcohol by volume. Methanol Fuel containing methanol (methyl) or wood alcohol may be used, providing there is no more than 5% methanol by volume. Use of fuel (gasohol) that contains more than 5% methanol can corrode metal fuel system components and damage plastic and rubber parts. GASOLINE Unleaded gasoline must be used. Minimum octane rating: 87 [(R+M)/2] Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair WARNING: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing fuel system components. After relieving system pressure, a small amount of fuel may be released when servicing fuel lines or connections. In order to reduce the chance of personal injury, cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when disconnect is completed. When servicing the fuel system use the following precautions: a. Put a "CAUTION FLAMMABLE" sign in the workshop. b. Be sure shop is supplied with an adequate fire extinguisher. c. Be sure to disconnect battery ground cable before any service work is done. d. Use a suitable container to catch any fuel that may leak from the system during service. e. Always relieve fuel system pressure before disconnecting any lines. f. If the key must be turned ON while servicing the fuel system, always disconnect or disable the ignition, to insure no sparks occur near fuel vapors. g. NEVER turn the ignition on while servicing the fuel system unless the electric fuel pump is disabled. PROCEDURE: 1. Loosen fuel filler cap to relieve tank vapor pressure. 2. Raise the vehicle and disconnect fuel pump electrical connector at fuel tank. 3. Lower vehicle. 4. START engine and RUN until fuel supply remaining in fuel pipes is consumed. Engage starter for 3 seconds to relieve the remaining fuel pressure. 5. Perform required tests or repairs. 6. Raise vehicle and reconnect fuel pump electrical connector at fuel tank. 7. START vehicle for 10 seconds. Shut vehicle OFF and check for leaks. 8. Retighten the fuel tank cap. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Maintenance Cleaning > Page 2446 Fuel Injector: Technical Service Bulletins Multec Port Fuel Injectors - Cleaner Precautions Number: 91-312-6E Section: 6E Date: MAY 1991 Corp. Bulletin No.: 116502R Subject: MULTEC PORT FUEL INJECTORS/CLEANING Month and Year: 1986-90 CELEBRITY 1986-91 CAMARO, CAVALIER, CORVETTE 1987-91 CORSICA, BERETTA 1990-91 LUMINA, STORM Figure 1 THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-28O-6E, DATED APRIL 1991. THE STORM HAS BEEN ADDED. ALL COPIES OF 91-280-6E SHOULD BE DISCARDED. This bulletin has been written to inform technicians of possible damage to Multec port fuel injectors as a result of cleaning. The ball and seat design of the Multec port fuel injectors eliminates the need of ever having to use an injector cleaner. By design, the fuel metering portions of the injector are not directly exposed to the intake manifold gases that are responsible for the build-up of deposits that can cause injectors to clog. (see Figure 1). Some of these cleaners may contain high percentages of methanol and other solvents that cause damage to the injectors' coil wire insulation. Damaged insulation results in low resistance or shorted injectors. Also, high percentages of methanol or other solvents can increase friction at the injectors'critical bearing surfaces, resulting in premature wear. General Motors has conducted extensive injector cleaning studies to determine effectiveness. There is no confirmed evidence that cleaning Multec port fuel injectors has resolved a vehicle driveability problem. In addition, suppliers of various injector cleaners may claim that their product can also clean intake valve deposits. General Motors laboratory tests have shown that injector cleaners have little or no effect on intake valve deposits. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Maintenance Cleaning > Page 2447 General Motors maintains the position that Multec port fuel injectors should not be cleaned. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Maintenance Cleaning > Page 2448 Fuel Injector: Technical Service Bulletins Tools - Introduction Of The Fuel Injector Tester NO.: 93-I-39 DATE: June, 1993 GROUP: 6 CORP. NO.: 316501R SUBJECT: INFORMATION ON THE INTRODUCTION OF THE FUEL INJECTOR TESTER TOOL J - 39021 This bulletin is being revised to add information about the coil test and a list of driveability problems. In February, 1993, Kent-Moore shipped a new Fuel Injector Tester, tool J-39021, as part of the Essential Tool Program. This tool has the capability of performing injector balance and coil tests on all GM and many non-GM fuel injection systems. The injector balance test is one familiar to most technicians where fuel pressure drop is measured as an injector is energized for a set period of time. This fuel pressure drop is compared to that of the other injectors in the vehicle or a published standard. The injector coil test is a new test whereby the injector's resistance is measured during normal gperation by feeding a fixed current through the injector and measuring the voltage across the injector. Injector coil failures are more accurately detected using this method than by simply measuring the injectors resistance with an ohmmeter. Refer to the instructions included with the tool for testing procedures. This tool, and the injector coil test specifically, were developed to detect deterioration of injector coils due to the introduction of injector cleaners and fuel blends containing high levels of alcohol. Alcohol and water carried by the alcohol may attack and corrode injector coils resulting in a change in coil resistance and one or more of the following driveability symptoms: ^ rough idle ^ engine miss/surge ^ stall after start/hard start ^ fails emission test ^ poor fuel economy ^ exhaust odor The injector coil test procedure also requires the use of the Digital Voltmeter, J-39200, to measure the voltage across the injector during the test. The Fuel Injector Tester, J-39021, supplies one of three fixed current values throughout the duration of the test. Selection of the supply current value (0.5, 2.5, or 4.0 amps) is based on the injector's specified resistance. When the push-to-start-test button is pressed, the tool energizes the injector coil for five seconds. The condition of the injector coil (pass/fail) is determined by the voltage reading displayed on the voltmeter while the injector is energized. Instructions and specifications for most GM fuel injectors are included with the tool. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Injector Resistance, Application Chart & J-39021 Tester Values Fuel Injector Resistance, Application & Tester Specifications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Injector Resistance, Application Chart & J-39021 Tester Values > Page 2451 Fuel Injector: Specifications J-39021 Injector Tester Kent-Moore Fuel Injector Tester, tool J-39021, has the capability of performing injector balance and coil tests on all GM and many non-GM fuel injection systems. In addition to the familiar fuel pressure drop test, the injector coil test is a new test whereby the injector's resistance is measured during normal operation by feeding a fixed current through the injector and measuring the voltage drop across the injector. Injector coil failures are more accurately detected using this method than by simply measuring the injector's resistance with an ohmmeter. Refer to the instructions included with the tool. For further information, refer to TSB 93-6E-14, dated June 1993. (Corp. Ref. No.: 316501R) NOTE: Measuring injector resistance is not a fool-proof method of determining the condition of the injectors. A Fuel Injector Balance Test will more accurately determine the mechanical condition of the injector, while the injector resistance will determine the electrical condition of the injector. If available, use applicable C-Charts at Computers and Control Systems, Testing and Inspection. You should also start at Diagnostic System Check if you have not already done so. See: Computers and Control Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2452 Fuel Injector: Description and Operation Model 700 TBI Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 2453 Model 700 TBI - Exploded View PURPOSE The fuel injectors are solenoid activated, controlled by the ECM. The injector provides a precise amount of atomized fuel to the engine cylinder for combustion. OPERATION The ECM turns on the solenoids, which lifts a normally closed ball off a seat. Fuel, under pressure, is injected in a conical spray pattern at the walls of the throttle body bore above the throttle valve. The fuel that is not used by the injectors passes through the fuel pressure regulator before being returned to the fuel tank. DIAGNOSTIC NOTES An injector that is stuck partly open would cause loss of pressure after engine shut down, so long crank times would be noticed on some engines. Dieseling could also occur because some fuel could be delivered to the engine after the ignition is turned "OFF." Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Balance Test Procedure - TBI Fuel Injector: Testing and Inspection Fuel Injector Balance Test Procedure - TBI NOTE: An injector balance test is not used for this Throttle Body Injection system. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Balance Test Procedure - TBI > Page 2456 Fuel Injector: Testing and Inspection Fuel Injector Cleaning Procedure Cleaning of injectors on throttle body injection units is not normally required or recommended. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Balance Test Procedure - TBI > Page 2457 Fuel Injector: Testing and Inspection Measuring Injector Resistance / Using J-39021 Injector Tester Kent-Moore Fuel Injector Tester, tool J-39021, has the capability of performing injector balance and coil tests on all GM and many non-GM fuel injection systems. In addition to the familiar fuel pressure drop test, the injector coil test is a new test whereby the injector's resistance is measured during normal operation by feeding a fixed current through the injector and measuring the voltage drop across the injector. Injector coil failures are more accurately detected using this method than by simply measuring the injector's resistance with an ohmmeter. Refer to the instructions included with the tool. For further information, refer to TSB 93-6E-14, dated June 1993. (Corp. Ref. No.: 316501R) NOTE: Measuring injector resistance is not a fool-proof method of determining the condition of the injectors. A Fuel Injector Balance Test will more accurately determine the mechanical condition of the injector, while the injector resistance will determine the electrical condition of the injector. If available, use applicable C-Charts at Computers and Control Systems, Testing and Inspection. You should also start at Diagnostic System Check if you have not already done so. See: Computers and Control Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 2458 Fuel Injector: Service and Repair Fuel Injector Removal View Removal Of TBI Fuel Injector REMOVAL 1. Relieve fuel pressure. See MAINTENANCE PROCEDURES. 2. Disconnect battery ground cable, then remove air cleaner assembly. 3. Disconnect electrical connector at fuel injector. 4. Remove fuel injector retainer screw and retainer. 5. Using a smooth object as a fulcrum, place screwdriver blade under ridge opposite electrical connector end of fuel injector and carefully pry it out. 6. Remove and discard O-rings. Fuel Injector Part Codes INSTALLATION 1. Lubricate replacement O-rings with clean engine oil, then install upper and lower O-rings ensuring that upper O-ring is in groove and the lower one is up flush against the filter. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 2459 2. Position fuel injector in fuel meter body with electrical connector facing cut-out for wire grommet. 3. Carefully push injector down into seat in cavity. 4. Replace injector retainer and retainer screw, making sure that retaining screw is coated with appropriate thread locking compound. 5. Reinstall electrical connector, then install air cleaner assembly. 6. Start engine for 10 seconds, shut off and check for fuel leaks. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 2460 Fuel Injector: Tools and Equipment Kent-Moore Fuel Injector Tester, tool J-39021, has the capability of performing injector balance and coil tests on all GM and many non-GM fuel injection systems. In addition to the familiar fuel pressure drop test, the injector coil test is a new test whereby the injector's resistance is measured during normal operation by feeding a fixed current through the injector and measuring the voltage drop across the injector. Injector coil failures are more accurately detected using this method than by simply measuring the injector's resistance with an ohmmeter. Refer to the instructions included with the tool. For further information, refer to TSB 93-6E-14, dated June 1993. (Corp. Ref. No.: 316501R) NOTE: Measuring injector resistance is not a fool-proof method of determining the condition of the injectors. A Fuel Injector Balance Test will more accurately determine the mechanical condition of the injector, while the injector resistance will determine the electrical condition of the injector. If available, use applicable C-Charts at Computers and Control Systems, Testing and Inspection. You should also start at Diagnostic System Check if you have not already done so. See: Computers and Control Systems/Testing and Inspection Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 Operation PURPOSE The function of the regulator is to maintain a constant pressure differential across the injectors at all times. The pressure regulator compensates for engine load by increasing fuel pressure as engine vacuum drops. OPERATION The pressure regulator is a diaphragm-operated relief valve with engine vacuum on one side and and atmospheric pressure on the other side. The function of the regulator is to maintain a constant pressure to the injectors at all times, by controlling the flow in the return line by means of a calibrated bypass. DIAGNOSTIC NOTES The pressure regulator on this unit can be serviced separately. The system operates in an acceptable pressure range of 62 to 90 kPa (9 ti 13 psi). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 2464 Fuel Pressure Regulator: Service and Repair Model 700 TBI - Exploded View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 2465 TBI Fuel Pressure Regulator Removal REMOVAL 1. Relieve fuel pressure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect battery ground cable, then remove air cleaner assembly. 3. Remove pressure regulator attaching screws, while keeping the pressure regulator spring compressed by maintaining pressure on the pressure regulator cover. 4. Remove pressure regulator cover assembly which consists of: pressure regulator spring, spring seat, pressure regulator diaphragm assembly, and pressure regulator cover. 5. Inspect the pressure regulator valve seat for nicks, pitting, or irregularities. If damaged, replace fuel meter assembly. INSTALLATION 1. Install new pressure regulator diaphragm assembly, making sure that it is seated in the groove in the fuel meter body. 2. Install regulator spring seat and spring into cover assembly. 3. Install pressure regulator cover assembly. 4. Replace regulator attaching screws coated with appropriate thread locking compound. 5. Tighten regulator attaching screws to 2.5 Nm (22 lb. in.). 6. Reconnect negative battery cable. 7. With engine OFF, and ignition ON, check for fuel leaks. 8. Replace air cleaner assembly or air duct. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure, Engine Running ......................................................................................................................................................... 62-90 kPa (9-13 P.S.I.) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2470 Fuel Pressure: Testing and Inspection Fuel System Schematic WARNING: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before connecting a fuel pressure test. Refer to Fuel Pressure Release Procedure. CAUTION To reduce the risk of fire and personal injury: 1. It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge. 2. A small amount of fuel may be released when disconnecting the fuel lines. Cover the fuel lines with a shop towel to catch any fuel leaking out. Place the towel in an approved container once the lines are disconnected. 3. DO NOT pinch or restrict nylon fuel lines to avoid severing. If nylon fuel lines become kinked, and cannot be straightened, they must be replaced. 4. Wear safety glasses at all times. FUEL PRESSURE TESTING 1. Loosen fuel filler cap to relieve fuel tank pressure. (DO NOT tighten at this time.) 2. Raise the vehicle to disconnect the fuel pump electrical connector, then lower the vehicle. 3. Start and run the engine until the residual fuel is consumed. Engage starter for three seconds to assure fuel pressure relief. 4. Disconnect the negative battery cable, and locate the fuel feed pressure line. 5. Connect fuel pressure gage, J-29658-B, in between the fuel feed line and the TBI unit. Use the appropriate adapters. 6. Raise the vehicle to connect the fuel pump electrical connector, then lower the vehicle. 7. Connect the negative battery terminal. 8. Perform fuel pressure checks. 9. Relieve the fuel system pressure. See steps 2 and 3. 10. Disconnect the negative battery terminal and remove fuel pressure gauge. 11. Tighten fuel filler cap and connect the negative battery terminal. 12. Cycle the ignition switch twice, waiting ten seconds between cycles. Check for fuel leaks. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay And In-line Fuse. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2474 Fuel Pump Relay: Description and Operation Wiring Diagram For Fuel Pump Relay When the key is first turned ON, without the engine running, the ECM will turn the fuel pump relay ON for two seconds. This builds up the fuel pressure to normal operating pressure. If the engine is not started within two seconds, the ECM will shut the fuel pump OFF and wait until ignition reference pulses are present. As soon as the engine is cranked, the ECM turns the relay ON, which powers the fuel pump. The ECM continues to power the fuel pump during engine operation. If the fuel pump relay fails, it is backed up by the oil pressure switch, which continues to operate the fuel pump as long as oil pressure remains above 28.0 kPa (4 psi). - A faulty fuel pump relay can result in long cranking times, particularly if the engine is cold. - An inoperative fuel pump would cause a no start condition. A fuel pump which does not provide enough pressure can result in poor performance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2475 Fuel Pump Relay: Testing and Inspection Wiring Diagram For Fuel Pump Relay When the key is first turned ON, without the engine running, the ECM will turn the fuel pump relay ON for two seconds. This builds up the fuel pressure to normal operating pressure. If the engine is not started within two seconds, the ECM will shut the fuel pump OFF and wait until ignition reference pulses are present. As soon as the engine is cranked, the ECM turns the relay ON, which powers the fuel pump. The ECM continues to power the fuel pump during engine operation. If the fuel pump relay fails, it is backed up by the oil pressure switch, which continues to operate the fuel pump as long as oil pressure remains above 28.0 kPa (4 psi). - A faulty fuel pump relay can result in long cranking times, particularly if the engine is cold. - An inoperative fuel pump would cause a no start condition. A fuel pump which does not provide enough pressure can result in poor performance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2476 Fuel Pump Relay: Service and Repair Fuel Pump Relay And In-line Fuse. NOTE: The fuel pump relay is located in the engine compartment, attached to the relay bracket mounted on the dash. Other than checking for loose connections the only service on the fuel pump relay is replacement. PROCEDURE 1. Verify that the ignition switch is in the "OFF" position. 2. Disconnect the wiring harness plug. 3. Remove the fuel pump relay. 4. Install the new fuel pump relay. 5. Connect the wiring harness plug securely. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation Fuel Return Line: Description and Operation Engine Fuel Lines. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Page 2480 Fuel Tank Unit And Lines (Typical) FUEL TANK The fuel tank is located under the rear of the vehicle and is the fuel reservoir. The tank has a vertical baffle installed to prevent fuel slosh. The fuel pump and fuel level sending unit assembly are mounted in the fuel tank as one assembly. The fuel tank assembly also consists of the fuel filler neck and filler cap. FUEL FILLER NECK To help prevent refueling with leaded fuel, the fuel filler neck has a built-in restrictor and deflector. The opening of the restrictor will accept only the smaller unleaded gasoline nozzle which must be fully inserted to bypass the deflector. Attempted refueling with a leaded fuel nozzle will result in fuel splashing back out of the filler neck. FUEL TANK FILLER CAP The fuel tank filler neck is equipped with a screw type cap. The threaded part of the cap requires several turns counterclockwise to remove. The long threaded area was designed to allow any remaining fuel tank pressure to escape during the cap removal operation. A ratchet type torque limiting device prevents over-tightening. To install, turn the cap clockwise until a clicking noise is heard. This signals that the correct torque has been reached and the cap is fully seated. NOTE: If a fuel filler cap requires replacement, only a cap with the same features should be used. Failure to use the correct cap can result in a serious malfunction of the system. FUEL AND VAPOR PIPES The fuel feed and return pipes extend from the fuel pump/gauge sending unit to the engine compartment. The pipes are secured to the underbody with clip and screw assemblies. Both fuel feed pipes and return pipe must be properly routed and retained, and should be inspected occasionally for leaks, kinks, or dents. If evidence of dirt is found in the fuel injector assembly or fuel filter during disassembly, the pipes should be disconnected and blown out. Check the fuel strainer on the fuel pump/fuel gauge assembly for damage or omission. Screw fittings on the fuel line pipes utilize O-rings for the fuel feed and return pipes. Two sizes are used and are not interchangeable. The vapor pipe extends from the fuel pump/gauge assembly to the canister. However, it may not follow the same route as the fuel feed pipe. Due to the fact that the fuel pipes/hoses are under high pressure on fuel injected systems these systems require special consideration for service. FUEL LINE O-RINGS The fuel line O-rings used are made of Viton. They are brown in color. Viton is less affected than rubber by the additives used in many fuels. Therefore, rubber should not be used. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Page 2481 Fuel Return Line: Service and Repair Engine Fuel Lines. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Page 2482 Fuel Tank Unit And Lines (Typical) Fuel Filter And Lines WARNING: Always keep a dry chemical (Class B) type fire extinguisher near the work area. A small amount of fuel may be released when servicing fuel lines or connections. In order to reduce the chance of fire or personal injury, cover the fuel lines or fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when the disconnect is complete. Relieve the fuel system pressure before attempting any repairs. See MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF. When replacing fuel feed and return pipes, always replace them with original equipment or parts that meet GM specifications for those parts. The replacement pipe must have the same type fittings as the original pipes to ensure the integrity of the connection. NOTE: Do not use copper or aluminum tubing to replace steel tubing. Only tubing meeting the 124M specification or its equivalent is capable of meeting all pressure and vibration characteristics necessary to ensure the durability standard required. Many of the feed and return pipes use screw couplings with O-rings. Any time these fittings are loosened to service or to replace components, ensure that: ^ A back-up wrench is used to loosen and tighten fittings. ^ Check all O-rings at these locations (if applicable) for cuts or any damage and replace as necessary. ^ Use correct torque when tightening these fittings. ^ Inspect all pipes for kinks, leaks or dents. ^ Pipes must be properly secured to the frame to prevent chafing. A minimum of 6 mm (1/4 inch) clearance must be maintained around a pipe to prevent contact or chaffing. ^ Fuel feed and return pipes are secured to the underbody with clamps and screw assemblies. ^ Follow the same routing as the original pipe. ^ Fuel pipes must not contact the fuel tank or underbody at any point. FUEL AND VAPOR PIPE REPAIR: When it is impractical to replace an entire fuel line to repair localized damage, use the following procedure: ^ When rubber hose is used to replace pipe, use only reinforced fuel-resistant hose which is identified with the word "Fluoroelastomer" on the hose. The inside diameter of the hose must match the outside pipe diameter. ^ Do not use rubber hose within 100 mm (4 inches) of any part of the exhaust system, or within 254 mm (10 inches) of the catalytic converter. ^ In repairable areas, cut a piece of hose 100 mm (4 inches) longer than the portion of line removed. If more than a 6 inch 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 inches). ^ Follow the same routing as the original pipe. ^ Cut the ends of the pipe, remaining on the car, square with a tubing cutter. Using the first step of a double flaring tool, form a bead on the end of each pipe section. If the pipe is too corroded to withstand the beading operation without damage, the pipe should be replaced. If a new section of pipe is used, form a bead on both ends of it also. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Page 2483 ^ Use a screw type hose clamp NO. #2494772, or equivalent. Slide the clamps onto the pipe and push hoses 51 mm (2 inches) onto each portion of the fuel pipe. Tighten the clamps on each side of the repair. ^ Pipes must be properly secured to the frame to prevent chaffing. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation Fuel Supply Line: Description and Operation Engine Fuel Lines. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Page 2487 Fuel Tank Unit And Lines (Typical) FUEL TANK The fuel tank is located under the rear of the vehicle and is the fuel reservoir. The tank has a vertical baffle installed to prevent fuel slosh. The fuel pump and fuel level sending unit assembly are mounted in the fuel tank as one assembly. The fuel tank assembly also consists of the fuel filler neck and filler cap. FUEL FILLER NECK To help prevent refueling with leaded fuel, the fuel filler neck has a built-in restrictor and deflector. The opening of the restrictor will accept only the smaller unleaded gasoline nozzle which must be fully inserted to bypass the deflector. Attempted refueling with a leaded fuel nozzle will result in fuel splashing back out of the filler neck. FUEL TANK FILLER CAP The fuel tank filler neck is equipped with a screw type cap. The threaded part of the cap requires several turns counterclockwise to remove. The long threaded area was designed to allow any remaining fuel tank pressure to escape during the cap removal operation. A ratchet type torque limiting device prevents over-tightening. To install, turn the cap clockwise until a clicking noise is heard. This signals that the correct torque has been reached and the cap is fully seated. NOTE: If a fuel filler cap requires replacement, only a cap with the same features should be used. Failure to use the correct cap can result in a serious malfunction of the system. FUEL AND VAPOR PIPES The fuel feed and return pipes extend from the fuel pump/gauge sending unit to the engine compartment. The pipes are secured to the underbody with clip and screw assemblies. Both fuel feed pipes and return pipe must be properly routed and retained, and should be inspected occasionally for leaks, kinks, or dents. If evidence of dirt is found in the fuel injector assembly or fuel filter during disassembly, the pipes should be disconnected and blown out. Check the fuel strainer on the fuel pump/fuel gauge assembly for damage or omission. Screw fittings on the fuel line pipes utilize O-rings for the fuel feed and return pipes. Two sizes are used and are not interchangeable. The vapor pipe extends from the fuel pump/gauge assembly to the canister. However, it may not follow the same route as the fuel feed pipe. Due to the fact that the fuel pipes/hoses are under high pressure on fuel injected systems these systems require special consideration for service. FUEL LINE O-RINGS The fuel line O-rings used are made of Viton. They are brown in color. Viton is less affected than rubber by the additives used in many fuels. Therefore, rubber should not be used. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Page 2488 Fuel Supply Line: Service and Repair Engine Fuel Lines. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Page 2489 Fuel Tank Unit And Lines (Typical) Fuel Filter And Lines WARNING: Always keep a dry chemical (Class B) type fire extinguisher near the work area. A small amount of fuel may be released when servicing fuel lines or connections. In order to reduce the chance of fire or personal injury, cover the fuel lines or fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when the disconnect is complete. Relieve the fuel system pressure before attempting any repairs. See MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF. When replacing fuel feed and return pipes, always replace them with original equipment or parts that meet GM specifications for those parts. The replacement pipe must have the same type fittings as the original pipes to ensure the integrity of the connection. NOTE: Do not use copper or aluminum tubing to replace steel tubing. Only tubing meeting the 124M specification or its equivalent is capable of meeting all pressure and vibration characteristics necessary to ensure the durability standard required. Many of the feed and return pipes use screw couplings with O-rings. Any time these fittings are loosened to service or to replace components, ensure that: ^ A back-up wrench is used to loosen and tighten fittings. ^ Check all O-rings at these locations (if applicable) for cuts or any damage and replace as necessary. ^ Use correct torque when tightening these fittings. ^ Inspect all pipes for kinks, leaks or dents. ^ Pipes must be properly secured to the frame to prevent chafing. A minimum of 6 mm (1/4 inch) clearance must be maintained around a pipe to prevent contact or chaffing. ^ Fuel feed and return pipes are secured to the underbody with clamps and screw assemblies. ^ Follow the same routing as the original pipe. ^ Fuel pipes must not contact the fuel tank or underbody at any point. FUEL AND VAPOR PIPE REPAIR: When it is impractical to replace an entire fuel line to repair localized damage, use the following procedure: ^ When rubber hose is used to replace pipe, use only reinforced fuel-resistant hose which is identified with the word "Fluoroelastomer" on the hose. The inside diameter of the hose must match the outside pipe diameter. ^ Do not use rubber hose within 100 mm (4 inches) of any part of the exhaust system, or within 254 mm (10 inches) of the catalytic converter. ^ In repairable areas, cut a piece of hose 100 mm (4 inches) longer than the portion of line removed. If more than a 6 inch 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 inches). ^ Follow the same routing as the original pipe. ^ Cut the ends of the pipe, remaining on the car, square with a tubing cutter. Using the first step of a double flaring tool, form a bead on the end of each pipe section. If the pipe is too corroded to withstand the beading operation without damage, the pipe should be replaced. If a new section of pipe is used, form a bead on both ends of it also. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Page 2490 ^ Use a screw type hose clamp NO. #2494772, or equivalent. Slide the clamps onto the pipe and push hoses 51 mm (2 inches) onto each portion of the fuel pipe. Tighten the clamps on each side of the repair. ^ Pipes must be properly secured to the frame to prevent chaffing. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fuel Tank Unit And Lines (Typical) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2495 Fuel Pump/Fuel Gauge Sending Unit (typical) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2496 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit (typical) REMOVAL: 1. Before servicing the fuel pump the fuel system pressure must be relieved, see MAINTENANCE PROCEDURES. 2. Disconnect the negative battery cable. 3. Raise the car on a hoist. 4. Remove the fuel tank, 5. Remove the fuel tank sending unit and pump assembly by turning the cam lock ring counterclockwise. Lift assembly from the fuel tank. 6. Pull the fuel pump up into the attaching hose while pulling outward away from the bottom support. Take care to prevent damage to the rubber insulator and strainer during removal. After the pump assembly is clear of the bottom support, pull the pump assembly out of the rubber connector for removal. NOTE: Inspect the fuel pump attaching hose for any signs of deterioration. Also check the rubber sound insulator at the bottom of the pump. Replace damaged or deteriorated parts. INSTALLATION: 1. Push the fuel pump assembly into the attaching hose. 2. Position the fuel tank sending unit and pump assembly into the fuel tank. Use a new "O" ring seal. NOTE: Care should be taken not to fold over or twist the strainer when installing the sending unit as this will restrict the flow of fuel. Also, verify that the strainer does not block the full travel of the float arm. 3. Install cam lock over the assembly and lock by turning clockwise. 4. Reinstall fuel tank. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 2497 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations Idle Speed/Throttle Actuator - Electronic: Locations Top Of 2. Top Of Engine, On Throttle Body Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2501 Idle Speed/Throttle Actuator - Electronic: Description and Operation Idle Air Control Operation PURPOSE The purpose of the idle air control (IAC) valve is to provide a way for the engine control module (ECM) to control engine idle speed. OPERATION Engine idle speeds are controlled by the ECM through the Idle Air Control (IAC) valve mounted on the throttle body. The ECM sends voltage pulses to the IAC motor windings causing the IAC motor shaft to move in and out a given distance for each pulse, (referred to as IAC counts on a scan tool). This movement controls airflow around the throttle plates, which in turn, controls engine idle speed, on either a hot or cold engine. IAC valve pintle position counts can be seen by using a scan tool. 0 counts corresponds to fully closed passage, while 140 counts or more (depending on application) corresponds to full flow. While the IAC valve controls airflow through the throttle body, (and thus idle speed) a minimum amount of air flow goes past the throttle plates. The throttle plate position is set by the throttle stop screw and plugged at the factory to avoid unnecessary tampering. DIAGNOSTIC NOTES: ^ If the IAC valve is disconnected and reconnected with the engine running, the idle rpm may be wrong. In this case, the IAC has to be reset. ^ When servicing the IAC, it should only be disconnected or connected with the ignition OFF. This will keep from having to reset the IAC. ^ For diagnosis and testing procedures, see COMPUTERIZED ENGINE CONTROLS. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Testing and Inspection > Idle Air Control (IAC) Reset Procedure Idle Speed/Throttle Actuator - Electronic: Testing and Inspection Idle Air Control (IAC) Reset Procedure To reset the Idle Air Control (IAC) valve pintle position, proceed with the following: 1. Block the drive wheels, and apply the parking brake. Select "Engine rpm" on "Scan" tool. 2. Start the engine, and hold the engine speed above 2000 rpm. Select "Field Service Mode" for ten seconds (this will reset the IAC valve pintle position). 3. Exit "Field Service Mode," and allow the engine to return to idle. 4. Turn the ignition "OFF," then restart the engine and check for the proper idle operation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Testing and Inspection > Idle Air Control (IAC) Reset Procedure > Page 2504 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection Idle Air Control (IAC) System Check (Chart C-2C) Chart C-2C Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Testing and Inspection > Idle Air Control (IAC) Reset Procedure > Page 2505 Wiring Diagram For IAC System CIRCUIT DESCRIPTION: The ECM controls engine idle speed with the Idle Air Control (IAC) valve. To increase idle speed, the ECM retracts the IAC valve pintle away from its seat, allowing more air to pass by the throttle body. To decrease idle speed, it extends the IAC valve pintle towards its seat, reducing bypass air flow. A "Scan" tool will read the ECM commands to the IAC valve in counts. The higher the counts indicate more air bypass (higher idle). The lower the counts indicate less air is allowed to bypass (lower idle). TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. 1. The IAC tester is used to extend and retract the IAC valve. Valve movement is verified by an engine speed change. If no engine speed occurs, the valve can be retested when removed from the throttle body. 2. This step checks the quality of the IAC movement in step 1. Between 700 and 1500 rpm, the engine speed should change smoothly with each flash of the tester light for both extend and retract. If the IAC valve is retracted beyond the control range (approximately 1500 rpm), it may take many flashes in the extend position before the engine speed drops. This is normal on certain engines; fully extending the IAC may cause the engine to stall. 3. Steps 1 and 2 verified proper IAC valve operation. This step checks the IAC circuit. Each lamp on the node light should flash red and green while the IAC valve is cycled. While the sequence of colors are not important, if either the light is "OFF" or does not flash red and green, check the circuits for faults. Check for poor terminal contacts. DIAGNOSTIC AIDS: A slow, unstable idle may be caused by a non-IAC system problem that cannot be overcome by the IAC valve. Out of control range IAC "Scan" tool counts will be above 60 if idle is too low, and "0" counts if the idle is too high. If the idle speed is too high, turn the ignition "OFF" to stop the engine. Turn the ignition "ON" without the engine running. Wait 45 seconds for the IAC valve pintle to seat, then disconnect the IAC valve. The following checks should be made to repair a non-IAC system problem: a. Vacuum leak (High Idle) - If idle is too high, stop the engine. Fully extend (low) IAC with tester. Start engine. If idle speed is above 800 rpm, locate and correct vacuum leak including PCV system. Also check for binding of throttle blade or linkage. b. System Too Lean (High Air/Fuel Ratio) - The idle speed may be too high or too low. Engine speed may vary up and down and disconnecting the IAC valve does not help. A Code 44 may set. "Scan" O2 voltage will be less than 300 mv (0.3 volt). Check for low regulated fuel pressure , or water in fuel. A fixed oxygen sonsor voltage above 800 mv (0.8 volts) may be contaminated by silicone. A Code 45 may be stored in the computer. c. System Too Rich (Low Air/Fuel Ratio - The idle speed will be too low. Scaning IAC counts will usually be above 80. System is obviously rich and may exhibit black smoke in exhaust. "Scan" tool O2 voltage will be fixed above 800 mv (0.8 volt). Check for high fuel pressure, leaking or sticking injector. Silicone contaminated O2 sensors "Scan" voltage will be slow to respond. d. Throttle Body - Remove IAC valve and inspect bore for foreign material. e. IAC Valve Electrical Connections - IAC valve harness connections should be carefully checked for proper contact. f. PCV Valve - An incorrect or faulty PCV valve may result in an incorrect idle speed. g. Refer to "Rough, Unstable, Incorrect Idle or Stalling" in DIAGNOSIS BY SYMPTOM. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Testing and Inspection > Page 2506 Idle Speed/Throttle Actuator - Electronic: Adjustments NOTE: The minimum idle air rate is set at the factory with a stop screw, which is covered with a tamper plug. This setting allows enough air flow by the throttle valves to cause the IAC valve pintle to be positioned a calibrated number of steps (counts), from the seat, during "controlled" idle operation. If the IAC valve is disconnected and reconnected with the engine running, the idle speed may be wrong. In this case, the IAC valve can be reset by doing the following: The IAC valve will be reset by the computer when the vehicle speed exceeds 43 MPH while the engine speed is above 2000 RPM or when the diagnostic test connector is grounded when the engine RPM is above 2000 RPM. To reset the Idle Air Control (IAC) valve pintle position, proceed with the following: 1. Block the drive wheels, and apply the parking brake. Select "Engine rpm" on "Scan" tool. If a scan tool is not available, use a tachometer. 2. Start the engine, and hold the engine speed above 2000 rpm. Select "Field Service Mode" for ten seconds (this will reset the IAC valve pintle position). If a scan tool is not available, jumper pins A to B on the ALDL diagnostic connector. 3. Exit "Field Service Mode," (or remove jumper from ALDL connector) and allow the engine to return to idle. 4. Turn the ignition "OFF," then restart the engine and check for the proper idle operation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Service and Repair > Computer Command Control - Throttle Body Fuel Injection Idle Speed/Throttle Actuator - Electronic: Service and Repair Computer Command Control Throttle Body Fuel Injection To reset the Idle Air Control (IAC) valve pintle position, proceed with the following: 1. Block the drive wheels, and apply the parking brake. Select "Engine rpm" on "Scan" tool. 2. Start the engine, and hold the engine speed above 2000 rpm. Select "Field Service Mode" for ten seconds (this will reset the IAC valve pintle position). 3. Exit "Field Service Mode," and allow the engine to return to idle. 4. Turn the ignition "OFF," then restart the engine and check for the proper idle operation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Service and Repair > Computer Command Control - Throttle Body Fuel Injection > Page 2509 Idle Speed/Throttle Actuator - Electronic: Service and Repair Idle Air Control (IAC) Valve Replacement Model 700 TBI - Exploded View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Service and Repair > Computer Command Control - Throttle Body Fuel Injection > Page 2510 Flange Mounted IAC Valve REMOVAL: 1. Verify that the ignition switch is in the OFF position. 2. Disconnect the electrical connector. 3. Remove the IAC valve assembly and O-ring, discard O-ring. CAUTION: On IAC valves that have been in service, Do Not push or pull on the IAC valve pintle. The force required to move the pintle may damage the threads on the worm drive. Do Not soak the IAC valve in any liquid solvent or cleaner, as damage may result. NOTE: ^ Clean the IAC valve gasket sealing surface, pintle valve seat, and air passage: a. Use carburetor cleaner to remove carbon deposits. Do Not use a cleaner that contains Methyl Ethyl Ketone. It is an extremely strong solvent, and not necessary for this type of deposit. b. Shiny spots on the pintle or pintle seat are normal, and do not indicate misalignment or a bent pintle shaft. c. If the air passage has heavy deposits, remove the throttle body for complete cleaning. ^ If installing a new IAC valve, be sure to replace with an identical part. IAC valve pintle shape and diameter are designed for the specific application. INSTALLATION: 1. If installing a new IAC valve: a. Measure the distance between the tip of the IAC valve pintle and the mounting surface. b. If greater than 28 mm, use finger pressure to slowly retract the pintle. The force required to retract the pintle of a new valve will not cause damage to the valve. 2. Install the IAC valve assembly with a new O-ring, and reinstall IAC valve assembly, making sure that attaching screws are coated with appropriate thread locking compound. 3. Connect the electrical connector. 4. Reset the IAC valve pintle position: ^ The IAC valve will be reset by the computer when the vehicle speed exceeds 43 MPH while the engine speed is above 2000 RPM or when the diagnostic test connector is grounded when the engine RPM is above 2000 RPM. 5. Test drive the vehicle and check for proper idle operation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations Rear Of Engine RH rear of engine, below intake manifold Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 2514 Oil Pressure Switch (For Fuel Pump): Description and Operation Wiring Diagram For Fuel Pump Relay As a back-up system to the fuel pump relay, the fuel pump can also be turned ON by the oil pressure switch. The oil pressure switch is a normally open switch which closes when oil pressure reaches about 28.0 kPa (4.0 psi). If the fuel pump relay fails, the oil pressure switch will power the fuel pump. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 2515 Oil Pressure Switch (For Fuel Pump): Testing and Inspection Wiring Diagram For Fuel Pump Relay The oil pressure switch is mounted on the engine. This switch operates as a parallel power supply with the fuel pump relay to supply battery voltage to the fuel pump. Voltage is supplied to the fuel pump after approximately 28 kPa (4 PSI) oil pressure is reached. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 2516 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch Located On RH Side Of Engine. Oil sender is located on right hand side of engine, under the DIS coils, under the intake manifold. Remove oil sender by using correct tool on the base of the sending unit. Do not use the body of the oil sender for installation/removal. Use appropriate sealer on threads. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay And In-line Fuse. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2521 Fuel Pump Relay: Description and Operation Wiring Diagram For Fuel Pump Relay When the key is first turned ON, without the engine running, the ECM will turn the fuel pump relay ON for two seconds. This builds up the fuel pressure to normal operating pressure. If the engine is not started within two seconds, the ECM will shut the fuel pump OFF and wait until ignition reference pulses are present. As soon as the engine is cranked, the ECM turns the relay ON, which powers the fuel pump. The ECM continues to power the fuel pump during engine operation. If the fuel pump relay fails, it is backed up by the oil pressure switch, which continues to operate the fuel pump as long as oil pressure remains above 28.0 kPa (4 psi). - A faulty fuel pump relay can result in long cranking times, particularly if the engine is cold. - An inoperative fuel pump would cause a no start condition. A fuel pump which does not provide enough pressure can result in poor performance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2522 Fuel Pump Relay: Testing and Inspection Wiring Diagram For Fuel Pump Relay When the key is first turned ON, without the engine running, the ECM will turn the fuel pump relay ON for two seconds. This builds up the fuel pressure to normal operating pressure. If the engine is not started within two seconds, the ECM will shut the fuel pump OFF and wait until ignition reference pulses are present. As soon as the engine is cranked, the ECM turns the relay ON, which powers the fuel pump. The ECM continues to power the fuel pump during engine operation. If the fuel pump relay fails, it is backed up by the oil pressure switch, which continues to operate the fuel pump as long as oil pressure remains above 28.0 kPa (4 psi). - A faulty fuel pump relay can result in long cranking times, particularly if the engine is cold. - An inoperative fuel pump would cause a no start condition. A fuel pump which does not provide enough pressure can result in poor performance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2523 Fuel Pump Relay: Service and Repair Fuel Pump Relay And In-line Fuse. NOTE: The fuel pump relay is located in the engine compartment, attached to the relay bracket mounted on the dash. Other than checking for loose connections the only service on the fuel pump relay is replacement. PROCEDURE 1. Verify that the ignition switch is in the "OFF" position. 2. Disconnect the wiring harness plug. 3. Remove the fuel pump relay. 4. Install the new fuel pump relay. 5. Connect the wiring harness plug securely. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations Oil Pressure Switch (For Fuel Pump): Locations Rear Of Engine RH rear of engine, below intake manifold Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 2528 Oil Pressure Switch (For Fuel Pump): Description and Operation Wiring Diagram For Fuel Pump Relay As a back-up system to the fuel pump relay, the fuel pump can also be turned ON by the oil pressure switch. The oil pressure switch is a normally open switch which closes when oil pressure reaches about 28.0 kPa (4.0 psi). If the fuel pump relay fails, the oil pressure switch will power the fuel pump. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 2529 Oil Pressure Switch (For Fuel Pump): Testing and Inspection Wiring Diagram For Fuel Pump Relay The oil pressure switch is mounted on the engine. This switch operates as a parallel power supply with the fuel pump relay to supply battery voltage to the fuel pump. Voltage is supplied to the fuel pump after approximately 28 kPa (4 PSI) oil pressure is reached. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 2530 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch Located On RH Side Of Engine. Oil sender is located on right hand side of engine, under the DIS coils, under the intake manifold. Remove oil sender by using correct tool on the base of the sending unit. Do not use the body of the oil sender for installation/removal. Use appropriate sealer on threads. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2535 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor 18 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2536 Throttle Position Sensor: Locations Top Rear Of 2.2L Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 2L/4-134 Engine. 1991 Cavalier Engine Component Locations. Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2537 Throttle Position Sensor: Description and Operation Typical Throttle Position Sensor (TPS) Wiring Throttle Position Sensor PURPOSE The function of the Throttle Position Sensor (TPS) is to sense the current throttle valve position and relay that information to the ECM. Throttle position information allows the ECM to generate the required injector control signals (base pulse). OPERATION If the TPS senses a opening throttle, a voltage signal indicating this condition is sent to the ECM. The ECM then increases the injector pulse width, permitting increased fuel flow. As the throttle valve rotates in response to movement of the accelerator pedal, the throttle shaft transfers this rotation to the TPS. A potentiometer (variable resistor) within the TPS assembly changes its resistance (and voltage drop) in proportion to throttle movement. By applying a reference voltage (5.0 volts) to the TPS input, a varying voltage (reflecting throttle position) is available at the TPS output. For example, approximately 2.5 volts results from a 50% throttle valve opening (depending on TPS calibration). The voltage output from the TPS assembly is routed to the ECM for use in determining throttle position. If the TPS is held in a wide open throttle (WOT) position during engine start, the ECM will interpret this as a clear flood mode. The ECM will then pulse the injectors at a ratio of 20 to 1 in order to clear a flooded condition. The ECM will hold this injector rate as long as the throttle stays wide open, and the engine speed is below 600 rpm. LOCATION The Throttle Position Sensor (TPS), is mounted on the side of the throttle body opposite the throttle lever assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2538 Throttle Position Sensor: Adjustments TPS Adjustment Check The Throttle Position Sensor (TPS) is not adjustable. The normal closed throttle position voltage is below 1.33 volts, and normal wide open throttle position voltage is approximately 5.0 volts. If these limits are not in specification, check for freedom of throttle movement, and accelerator pedal interference from carpets and other obstructions. If the problem is not corrected, replace the TPS. The ECM has the ability to self zero the TPS voltage if it is below approximately 1.33 volts. A TPS voltage that does not fall within 0.33 volts and 1.33 volts should be replaced after checking connections. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2539 Throttle Position Sensor: Service and Repair Model 700 TBI - Exploded View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2540 Throttle Position Sensor REMOVAL: 1. Disconnect the electrical connector. 2. Remove TPS attaching screws. 3. Remove the TPS. CAUTION: The TPS is an electrical component and must not be soaked in any liquid cleaner or solvent, as damage may result. INSTALLATION: 1. With the throttle valve in the closed position, install the TPS on the throttle shaft. Rotate counter clockwise to align mounting holes. 2. Install the TPS attaching screws, finger tighten only. 3. Tighten attaching screws to 2.0 N-m (18 lb. in.) 4. Check TPS voltage: a. Connect a scan tool to the ALDL connector. b. Turn the ignition switch ON. c. Select TPS voltage display on the scan tool, and check voltage. The TPS voltage should be less than 1.25 volts. If the reading is higher than 1.25 volts, check for binding throttle valve or throttle cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Throttle Body Attach Bolts 18 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 2544 TBI Assembly Mounting (typical). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Throttle Body Assembly Throttle Body: Description and Operation Throttle Body Assembly Model 700 TBI - Exploded View PURPOSE The purpose of the throttle body assembly is to control air and fuel flow into the engine. The throttle body assembly also provides the location for mounting of the tube module assembly and the Throttle Position Sensor (TPS). OPERATION The throttle valve within the throttle body is opened by the driver through the accelerator controls. During engine idle, the throttle valve is closed, and air flow is handled by the Idle Air Control (IAC) Valve. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Throttle Body Assembly > Page 2547 The TBI unit consists of two major assemblies: ^ Fuel meter body, which contains fuel injector and fuel pressure regulator. ^ Throttle body containing throttle valve, idle air control valve, throttle position sensor and the tube module assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Throttle Body Assembly > Page 2548 Throttle Body: Description and Operation Tube Module Assembly Model 700 TBI - Exploded View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Throttle Body Assembly > Page 2549 Tube Module Assembly (Typical) The throttle body assembly provides the location for mounting of the tube module assembly. Vacuum ports are located in the tube module assembly to direct vacuum from above or below the throttle plate as needed by various components. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Concealment Plug Removal Throttle Body: Service and Repair Concealment Plug Removal Stop Screw Plug Removal If necessary to adjust minimum idle speed, the concealment plug must first be removed. If soft plug is present, remove the stop screw plug by piercing it with an awl, then applying leverage. The screw is covered to discourage unauthorized adjustments. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Concealment Plug Removal > Page 2552 Throttle Body: Service and Repair Throttle Body Assembly Removal and Replacement TBI Assembly Mounting (typical). Model 700 TBI CAUTION: The throttle bore and valve deposits may be cleaned on the vehicle, using carburetor cleaner and a parts cleaning brush. Do Not use a cleaner that contains Methyl Ethyl Ketone. It is an extremely strong solvent, and not necessary for this type of deposit. ^ The throttle body parts may be cleaned following disassembly, in a cold immersion type cleaner such as GM X-55 or equivalent. ^ The throttle position sensor (TPS) and idle air control (IAC) valve should not come in contact with solvent or cleaner, as they are electrical components and may be damaged. REMOVAL: 1. Relief fuel pressure. See: Fuel Filter/Fuel Pressure Release/Service and Repair Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Concealment Plug Removal > Page 2553 2. Disconnect the negative battery cable. 3. Remove fuel feed and return lines. Use a backup fuel line wrench on the TBI fuel nuts to prevent them from turning. 4. Remove and discard the fuel line O-rings. 5. Disconnect the IAC valve and TPS electrical connectors. 6. Disconnect the vacuum lines. 7. Disconnect the throttle, T.V, (transmission control), and cruise control cables. 8. Remove the throttle body attaching bolts. 9. Remove the throttle body assembly and flange gasket, discard the gasket. 10. Clean the gasket sealing surfaces: ^ Use care in cleaning old gasket material from machined aluminum surfaces. Sharp tools may damage sealing surfaces. INSTALLATION: 1. Install the throttle body assembly with a new flange gasket. 2. Install the throttle body attaching bolts and tighten to 25 Nm (18 lb. ft.). 3. Install new O-rings on fuel lines. 4. Install fuel lines and tighten to 27 Nm (20 lb. ft.). Use backup fuel line wrench on the TBI fuel nuts to prevent them from turning. 5. Connect the throttle, T.V., and cruise control cables. NOTE: Make sure that the throttle and cruise control cables do not hold the throttle open. 6. Connect the vacuum lines. 7. Connect the IAC and TPS electrical connectors. 8. Connect the negative battery cable. 9. With the engine OFF, check to see that the accelerator pedal is free, depress the accelerator pedal to the floor and release. 10. Start engine and check for leaks. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Concealment Plug Removal > Page 2554 Throttle Body: Service and Repair Throttle Body Cleaning CAUTION: The throttle bore and valve deposits may be cleaned on the vehicle, using carburetor cleaner and a parts cleaning brush. Do Not use a cleaner that contains Methyl Ethyl Ketone. It is an extremely strong solvent, and not necessary for this type of deposit. ^ The throttle body parts may be cleaned following disassembly, in a cold immersion type cleaner such as GM X-55 or equivalent. ^ The Throttle Position Sensor (TPS) and Idle Air Control (IAC) valve should not come in contact with solvent or cleaner, as they are electrical components and may be damaged. Idle air control valves (new and used) have a special factory applied coating to the threads. If the valve is removed and is being reinstalled, avoid removing any of the thread locking compound that may be remaining on the threads. Clean IAC pintle valve seat, air passage and gasket sealing surface. Do not use cleaners that contain Methyl Ethyl Ketone. It is too strong of a solvent to be used on throttle body components. No further cleaning of throttle body components should be necessary. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Concealment Plug Removal > Page 2555 Throttle Body: Service and Repair Tube Module Assembly Removal Model 700 TBI - Exploded View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Concealment Plug Removal > Page 2556 Tube Module Assembly (Typical) REMOVAL 1. Remove air cleaner assembly or air duct. 2. Remove vacuum hose. 3. Remove tube module attaching screws. 4. Remove tube module assembly and gasket. Save the old gasket to match with the new gasket. Do not reuse the old gasket. 5. Clean sealing surfaces. INSTALLATION 1. Install tube module gasket. Visually match the old gasket to the new gasket. 2. Install tube module assembly. 3. Replace the attaching screws coated with appropriate thread locking compound. 4. Tighten tube module attaching screws to 3.0 N-m (27 lb. in.). 5. Reinstall electrical connector, then install air cleaner assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Locations Throttle Cable/Linkage: Locations Accelerator Controls - Engine Compartment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Locations > Page 2560 Accelerator Controls - Passenger Compartment Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Locations > Page 2561 Throttle Cable/Linkage: Adjustments Accelerator Controls - Passenger Compartment Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Locations > Page 2562 Accelerator Controls - Engine Compartment. The accelerator control system is cable type. There are no linkage adjustments. The specific cable for each application must be used. Only the specific replacement part will work. Check for correct opening and closing positions by operating the accelerator pedal. Make sure that the throttle valve reaches the wide open and fully closed throttle positions. If it does not, inspect for damaged or bent brackets, levers, or other components, or for poor carpet fit under the accelerator pedal. If any binding is present in the linkage, check for: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Locations > Page 2563 1. Proper routing of the throttle cable. 2. Kinked or damaged cable. 3. Free movement of: a. Throttle lever at the throttle body. b. Cable at throttle body or control lever/pulley. c. Accelerator lever at bearing support. d. Pedal at lever. Whenever disconnecting or replacing parts, lubricate the pivot points with Accelerator Linkage Lubricant 1052541 or equivalent. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Locations > Page 2564 Throttle Cable/Linkage: Service and Repair Accelerator Controls - Passenger Compartment Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Locations > Page 2565 Accelerator Controls - Engine Compartment. ACCELERATOR PEDAL: When performing service on the accelerator pedal, observe the following: ^ The braided portion of the accelerator cable assembly must not come in contact with the front of the dash sealer during assembly, repair, or replacement of the assembly. ^ The mounting surface between the support and dash panel must be free of insulation. The carpet and padding in the pedal and tunnel area must be positioned to lay flat and be free on wrinkles and bunches. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Locations > Page 2566 ^ Slip the accelerator control cable through the slot in the rod and then install the retainer in the rod, makeing sure it is seated. Use care when pressing the retainer into the hole in the rod to ensure that the cable is not kinked or damaged in any way. ^ After securing all components of the accelerator linkage, the linkage must operate freely without binding between full closed throttle and full wide open throttle. ^ Wires, hoses, cables or other obstructions must not be placed within 13 mm (1/2 inch) of the cable or the rod at any point in their travel. ACCELERATOR CONTROL CABLE: When performing service on the accelerator control cable, observe the following: ^ The retainer must be installed with the tangs secured overhead of the stud. ^ The conduit fitting at both ends of the cable must have the locking tangs expanded and locked in the attaching holes. ^ The flexible components (hoses, wires, conduits, etc.) must be routed within 50 mm (2 inches) of the moving parts of the accelerator linkage outboard of the support unless the routing is positively controlled. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2571 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor 18 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2572 Throttle Position Sensor: Locations Top Rear Of 2.2L Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 2L/4-134 Engine. 1991 Cavalier Engine Component Locations. Top Rear Of Engine, On LH Side Of Throttle Body Applicable to: 1991 Cavalier w/2.2L/4-134 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2573 Throttle Position Sensor: Description and Operation Typical Throttle Position Sensor (TPS) Wiring Throttle Position Sensor PURPOSE The function of the Throttle Position Sensor (TPS) is to sense the current throttle valve position and relay that information to the ECM. Throttle position information allows the ECM to generate the required injector control signals (base pulse). OPERATION If the TPS senses a opening throttle, a voltage signal indicating this condition is sent to the ECM. The ECM then increases the injector pulse width, permitting increased fuel flow. As the throttle valve rotates in response to movement of the accelerator pedal, the throttle shaft transfers this rotation to the TPS. A potentiometer (variable resistor) within the TPS assembly changes its resistance (and voltage drop) in proportion to throttle movement. By applying a reference voltage (5.0 volts) to the TPS input, a varying voltage (reflecting throttle position) is available at the TPS output. For example, approximately 2.5 volts results from a 50% throttle valve opening (depending on TPS calibration). The voltage output from the TPS assembly is routed to the ECM for use in determining throttle position. If the TPS is held in a wide open throttle (WOT) position during engine start, the ECM will interpret this as a clear flood mode. The ECM will then pulse the injectors at a ratio of 20 to 1 in order to clear a flooded condition. The ECM will hold this injector rate as long as the throttle stays wide open, and the engine speed is below 600 rpm. LOCATION The Throttle Position Sensor (TPS), is mounted on the side of the throttle body opposite the throttle lever assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2574 Throttle Position Sensor: Adjustments TPS Adjustment Check The Throttle Position Sensor (TPS) is not adjustable. The normal closed throttle position voltage is below 1.33 volts, and normal wide open throttle position voltage is approximately 5.0 volts. If these limits are not in specification, check for freedom of throttle movement, and accelerator pedal interference from carpets and other obstructions. If the problem is not corrected, replace the TPS. The ECM has the ability to self zero the TPS voltage if it is below approximately 1.33 volts. A TPS voltage that does not fall within 0.33 volts and 1.33 volts should be replaced after checking connections. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2575 Throttle Position Sensor: Service and Repair Model 700 TBI - Exploded View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2576 Throttle Position Sensor REMOVAL: 1. Disconnect the electrical connector. 2. Remove TPS attaching screws. 3. Remove the TPS. CAUTION: The TPS is an electrical component and must not be soaked in any liquid cleaner or solvent, as damage may result. INSTALLATION: 1. With the throttle valve in the closed position, install the TPS on the throttle shaft. Rotate counter clockwise to align mounting holes. 2. Install the TPS attaching screws, finger tighten only. 3. Tighten attaching screws to 2.0 N-m (18 lb. in.) 4. Check TPS voltage: a. Connect a scan tool to the ALDL connector. b. Turn the ignition switch ON. c. Select TPS voltage display on the scan tool, and check voltage. The TPS voltage should be less than 1.25 volts. If the reading is higher than 1.25 volts, check for binding throttle valve or throttle cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Ignition Firing Order Firing Order: Specifications Ignition Firing Order Firing Order ......................................................................................................................................... ....................................................................... 1-3-4-2 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations > Number 1 Cylinder Location Number One Cylinder: Locations Number 1 Cylinder Location NUMBER ONE CYLINDER LOCATION Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2591 Crankshaft Position Sensor: Mechanical Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2592 Rear Of Engine Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2593 Crankshaft Position Sensor: Description and Operation Typical DIS Crankshaft Sensor This crankshaft sensor is mounted remotely on the bottom side of the ignition module. This sensor protrudes into the block, within approximately 0.050" of the engine crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots cast into it, six of which are evenly spaced 60° apart. A seventh slot is spaced 10° from one of the other slots and serves to generate a "sync pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the crank pulses, the DIS module sends reference signals to the ECM which are used to indicate crankshaft position and engine speed. The ignition module will continue to send these reference pulses to the ECM at a rate of one for each 180° or crankshaft rotation. The ECM will activate the fuel injector based on the recognition of every other reference pulse beginning at a crankshaft position of 120° after top dead center. By comparing the time between pulses, the DIS module can recognize the pulse representing the seventh slot or "sync pulse," which starts the calculation of the ignition coil sequence. The second crank pulse following the "sync pulse" signals the "DIS" module to fire the #2/3 ignition coil and the fifth crank pulse signals the module to fire the #1/4 ignition coil. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug Wire <--> [Ignition Cable] > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug Wire: > 93356D > Oct > 92 > Engine - Miss, Hesitation, or Roughness Spark Plug Wire: Customer Interest Engine - Miss, Hesitation, or Roughness Number: 93-35-6D Section: 6D Date: OCT. 1992 Corporate Bulletin No.: 716404R ASE No.: A1, A8 Subject: ENGINE MISS HESITATION OR ROUGHNESS DUE TO PIERCED SECONDARY IGNITION COMPONENTS Model and Year: 1980-93 ALL PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 87-121, DATED MAY 1987. THE 1989-93 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 87-121 SHOULD BE DISCARDED. During the diagnosis procedure for an engine miss, hesitation or roughness, a spark plug or spark plug wire condition may be suspected. Several types of commercial or homemade diagnostic equipment required the secondary ignition boots or wire to be pierced. This is normally done to check for spark plug firing or to perform a cylinder balance test. Similarly the use of pliers or other such tools to disengage a spark plug boot may pierce or damage the boot or wire. Secondary ignition components should not be pierced for any reason. Piercing a spark plug wire and/or distributor boot may create a condition that will not be immediately apparent. Over time, the hole in the pierced boot may allow a ground path to develop creating a plug misfire condition. Heavily moisture laden air in the vicinity of the pierced boot may accelerate this effect. Piercing a secondary ignition wire creates a gap in the wire's conductive core. This gap is a point of high resistance. The current flow in the wire will increase to compensate for the higher wire resistance. Over time, the wire may fail creating a plug misfire condition. The time required for the condition to appear depends upon the extent of damage to the conductive core. To help prevent future condition that are spark plug wire related, do not pierce or otherwise damage any secondary ignition component. Only use diagnostic equipment containing an inductive pick-up to check for spark plug firing or to perform cylinder balance tests. When disengaging a spark plug boot from the spark plug, twist the flanged boot 1/2 turn then pull on the boot only to remove the wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug Wire <--> [Ignition Cable] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug Wire: > 93356D > Oct > 92 > Engine - Miss, Hesitation, or Roughness Spark Plug Wire: All Technical Service Bulletins Engine - Miss, Hesitation, or Roughness Number: 93-35-6D Section: 6D Date: OCT. 1992 Corporate Bulletin No.: 716404R ASE No.: A1, A8 Subject: ENGINE MISS HESITATION OR ROUGHNESS DUE TO PIERCED SECONDARY IGNITION COMPONENTS Model and Year: 1980-93 ALL PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 87-121, DATED MAY 1987. THE 1989-93 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 87-121 SHOULD BE DISCARDED. During the diagnosis procedure for an engine miss, hesitation or roughness, a spark plug or spark plug wire condition may be suspected. Several types of commercial or homemade diagnostic equipment required the secondary ignition boots or wire to be pierced. This is normally done to check for spark plug firing or to perform a cylinder balance test. Similarly the use of pliers or other such tools to disengage a spark plug boot may pierce or damage the boot or wire. Secondary ignition components should not be pierced for any reason. Piercing a spark plug wire and/or distributor boot may create a condition that will not be immediately apparent. Over time, the hole in the pierced boot may allow a ground path to develop creating a plug misfire condition. Heavily moisture laden air in the vicinity of the pierced boot may accelerate this effect. Piercing a secondary ignition wire creates a gap in the wire's conductive core. This gap is a point of high resistance. The current flow in the wire will increase to compensate for the higher wire resistance. Over time, the wire may fail creating a plug misfire condition. The time required for the condition to appear depends upon the extent of damage to the conductive core. To help prevent future condition that are spark plug wire related, do not pierce or otherwise damage any secondary ignition component. Only use diagnostic equipment containing an inductive pick-up to check for spark plug firing or to perform cylinder balance tests. When disengaging a spark plug boot from the spark plug, twist the flanged boot 1/2 turn then pull on the boot only to remove the wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug Wire <--> [Ignition Cable] > Component Information > Technical Service Bulletins > Page 2607 Spark Plug Wire: Specifications Ignition Wire Resistance: 1-15 in. ................................................................................................................................................. .......................................... 3000/10,000 ohms 15-25 in. ..................................................................... .................................................................................................................... 4000/15,000 ohms 25-35 in. ......................................................................................................................................................... ................................ 6000/20,000 ohms OVER 35 in. ......................................................................... .......................................................................................................... 8000/25,000 ohms Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug Wire <--> [Ignition Cable] > Component Information > Locations > Spark Plug Wire Routing Ignition Wire Location Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug Wire <--> [Ignition Cable] > Component Information > Locations > Spark Plug Wire Routing > Page 2610 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Ignition Coil: Specifications RESISTANCE VALUE Ignition Coil Secondary Coil Resistance ....................................................................................................................................................... less than 10,000 Ohms Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2614 Ignition Coil: Locations Engine Component Locations. Rear Of Engine, Below Exhaust Applicable to: 1991 Cavalier w/2.2L/4-134 Rear Of 2.2 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2615 Rear Of Engine, Below Exhaust Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2616 Ignition Coil: Description and Operation Coil Assembly Two twin tower ignition coils are combined into a single coil pack unit. This unit is mounted to the ignition module. Each coil provides the spark for two spark plugs at once simultaneously (waste spark distribution). Both coils can be replaced individually. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2617 Ignition Coil: Service and Repair REMOVAL 1. Disconnect negative battery cable. 2. Disconnect DIS electrical connectors. 3. Disconnect spark plug wires. (Note proper relationship of wires to coils). 4. Remove DIS assembly to block bolts (3). 5. Remove DIS assembly from engine. INSTALLATION 1. Install DIS assembly to engine. 2. Install DIS assembly to block bolts (3). Torque to 20-30 N-m (15-22 lbs ft). 3. Connect spark plug wires to proper coils. 4. Connect DIS electrical connectors. 5. Connect negative battery cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 914536D > Nov > 91 > Engine Stalls/No Start/Runs Rough/Code 42 Set Ignition Control Module: Customer Interest Engine - Stalls/No Start/Runs Rough/Code 42 Set Number: 91-453-6D Section: 6D Date: NOV. 1991 Corporate Bulletin No.: 136405 ASE No.: A6, A8 Subject: INTERMITTENT DIAGNOSTIC TROUBLE CODE 42 AND/OR DRIVEABILITY Model and Year: 1990-91 CAVALIER, CORSICA AND BERETTA WITH 2.2L ENGINE Condition: Some 1990-91 J and L vehicles equipped with the 2.2L (LM3) engine may intermittently exhibit one or more of the following conditions: * ECM Diagnostic Trouble Code 42 set, with no trouble found. * Engine stalling rough running, with no trouble found. * Intermittent no-start, with no trouble found. * ECM fuse blown, with no trouble found. Cause: DIS (Ignition) module lead wiring may be subject to a rub-through condition at the engine wiring harness bracket where it is mounted at the transaxle case. In addition, a similar condition may also exist on the transaxle case near the same location, from a sharp edge formed during case casting, when equipped with manual transaxle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 914536D > Nov > 91 > Engine Stalls/No Start/Runs Rough/Code 42 Set > Page 2626 Correction: Refer to Illustrations for location of repairs. Repair Procedure: - Remove secondary ignition wire bracket and wires, set aside. - Remove clutch cable retainer and cables, set aside. (Manual transaxle only.) - Un-clip engine wiring harness conduit from retainer, pull back conduit to expose harness. - Using common "black" electrical tape (locally attained part), begin taping approximately 5 inches back from the point where the main harness breaks out into 3 smaller harnesses. - While taping to the break-out point, push the individual smaller conduits back and tape up the harnesses as far as possible. * IMPORTANT: Tape wire harness with 4 layers of tape to insure proper insulation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 914536D > Nov > 91 > Engine Stalls/No Start/Runs Rough/Code 42 Set > Page 2627 * IMPORTANT: If any wires are worn through enough to short out against each other, if strands of wire are broken, or if an "open" wiring condition is found, refer to Section 8A of the applicable Service Manual for proper wiring repair. - Install wiring harness back into conduit. Before clipping retainer closed, pull the harness towards the center of the vehicle to remove any slack in the harness. This will keep the harness off the transaxle case and away from the transaxle controls. - Clip harness retainer into position. - Reinstall clutch cables and retainer. (Manual transaxle only). - Reinstall secondary ignition cables and bracket. Warranty and Labor Time Information: For taping and repositioning harness: Labor Code: T1789 Labor Time: 0.3 Hours For wiring repair, taping and repositioning of harness: Labor Code: T1789 Labor Time 0.4 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set Ignition Control Module: All Technical Service Bulletins Engine - Stalls/No Start/Runs Rough/Code 42 Set Number: 91-453-6D Section: 6D Date: NOV. 1991 Corporate Bulletin No.: 136405 ASE No.: A6, A8 Subject: INTERMITTENT DIAGNOSTIC TROUBLE CODE 42 AND/OR DRIVEABILITY Model and Year: 1990-91 CAVALIER, CORSICA AND BERETTA WITH 2.2L ENGINE Condition: Some 1990-91 J and L vehicles equipped with the 2.2L (LM3) engine may intermittently exhibit one or more of the following conditions: * ECM Diagnostic Trouble Code 42 set, with no trouble found. * Engine stalling rough running, with no trouble found. * Intermittent no-start, with no trouble found. * ECM fuse blown, with no trouble found. Cause: DIS (Ignition) module lead wiring may be subject to a rub-through condition at the engine wiring harness bracket where it is mounted at the transaxle case. In addition, a similar condition may also exist on the transaxle case near the same location, from a sharp edge formed during case casting, when equipped with manual transaxle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 2633 Correction: Refer to Illustrations for location of repairs. Repair Procedure: - Remove secondary ignition wire bracket and wires, set aside. - Remove clutch cable retainer and cables, set aside. (Manual transaxle only.) - Un-clip engine wiring harness conduit from retainer, pull back conduit to expose harness. - Using common "black" electrical tape (locally attained part), begin taping approximately 5 inches back from the point where the main harness breaks out into 3 smaller harnesses. - While taping to the break-out point, push the individual smaller conduits back and tape up the harnesses as far as possible. * IMPORTANT: Tape wire harness with 4 layers of tape to insure proper insulation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 2634 * IMPORTANT: If any wires are worn through enough to short out against each other, if strands of wire are broken, or if an "open" wiring condition is found, refer to Section 8A of the applicable Service Manual for proper wiring repair. - Install wiring harness back into conduit. Before clipping retainer closed, pull the harness towards the center of the vehicle to remove any slack in the harness. This will keep the harness off the transaxle case and away from the transaxle controls. - Clip harness retainer into position. - Reinstall clutch cables and retainer. (Manual transaxle only). - Reinstall secondary ignition cables and bracket. Warranty and Labor Time Information: For taping and repositioning harness: Labor Code: T1789 Labor Time: 0.3 Hours For wiring repair, taping and repositioning of harness: Labor Code: T1789 Labor Time 0.4 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2635 Ignition Control Module: Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2636 Ignition Control Module: Description and Operation Coil Assembly The DIS module monitors the crank sensor signals and based on these signals sends a reference signal to the ECM so that correct spark and fuel injector control can be maintained during all driving conditions. During cranking, the DIS module monitors the "sync pulse" to begin the ignition firing sequence, and below 400 rpm the module controls spark advance by triggering each of the three coils at a pre-determined interval based on engine speed only. Above 400 rpm, the ECM controls the spark timing through the module (EST), and compensates for all driving conditions. The DIS module must receive a "sync pulse" and then a crank signal in that order to enable the engine to start. The DIS module is not repairable. When a module is replaced, the remaining DIS module components must be transferred to the new module. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2637 Ignition Control Module: Service and Repair Coil Assembly Remove or Disconnect 1. Negative battery cable. 2. DIS assembly from engine. 3. Coils from assembly. 4. Module from assembly plate. Install or Connect 1. Module to assembly plate. (Carefully engage sensor to module terminals.) 2. Coils. 3. DIS assembly to engine. 4. Negative battery cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set Ignition Control Module: Customer Interest Engine - Stalls/No Start/Runs Rough/Code 42 Set Number: 91-453-6D Section: 6D Date: NOV. 1991 Corporate Bulletin No.: 136405 ASE No.: A6, A8 Subject: INTERMITTENT DIAGNOSTIC TROUBLE CODE 42 AND/OR DRIVEABILITY Model and Year: 1990-91 CAVALIER, CORSICA AND BERETTA WITH 2.2L ENGINE Condition: Some 1990-91 J and L vehicles equipped with the 2.2L (LM3) engine may intermittently exhibit one or more of the following conditions: * ECM Diagnostic Trouble Code 42 set, with no trouble found. * Engine stalling rough running, with no trouble found. * Intermittent no-start, with no trouble found. * ECM fuse blown, with no trouble found. Cause: DIS (Ignition) module lead wiring may be subject to a rub-through condition at the engine wiring harness bracket where it is mounted at the transaxle case. In addition, a similar condition may also exist on the transaxle case near the same location, from a sharp edge formed during case casting, when equipped with manual transaxle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 2650 Correction: Refer to Illustrations for location of repairs. Repair Procedure: - Remove secondary ignition wire bracket and wires, set aside. - Remove clutch cable retainer and cables, set aside. (Manual transaxle only.) - Un-clip engine wiring harness conduit from retainer, pull back conduit to expose harness. - Using common "black" electrical tape (locally attained part), begin taping approximately 5 inches back from the point where the main harness breaks out into 3 smaller harnesses. - While taping to the break-out point, push the individual smaller conduits back and tape up the harnesses as far as possible. * IMPORTANT: Tape wire harness with 4 layers of tape to insure proper insulation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest for Ignition Control Module: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 2651 * IMPORTANT: If any wires are worn through enough to short out against each other, if strands of wire are broken, or if an "open" wiring condition is found, refer to Section 8A of the applicable Service Manual for proper wiring repair. - Install wiring harness back into conduit. Before clipping retainer closed, pull the harness towards the center of the vehicle to remove any slack in the harness. This will keep the harness off the transaxle case and away from the transaxle controls. - Clip harness retainer into position. - Reinstall clutch cables and retainer. (Manual transaxle only). - Reinstall secondary ignition cables and bracket. Warranty and Labor Time Information: For taping and repositioning harness: Labor Code: T1789 Labor Time: 0.3 Hours For wiring repair, taping and repositioning of harness: Labor Code: T1789 Labor Time 0.4 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set Ignition Control Module: All Technical Service Bulletins Engine - Stalls/No Start/Runs Rough/Code 42 Set Number: 91-453-6D Section: 6D Date: NOV. 1991 Corporate Bulletin No.: 136405 ASE No.: A6, A8 Subject: INTERMITTENT DIAGNOSTIC TROUBLE CODE 42 AND/OR DRIVEABILITY Model and Year: 1990-91 CAVALIER, CORSICA AND BERETTA WITH 2.2L ENGINE Condition: Some 1990-91 J and L vehicles equipped with the 2.2L (LM3) engine may intermittently exhibit one or more of the following conditions: * ECM Diagnostic Trouble Code 42 set, with no trouble found. * Engine stalling rough running, with no trouble found. * Intermittent no-start, with no trouble found. * ECM fuse blown, with no trouble found. Cause: DIS (Ignition) module lead wiring may be subject to a rub-through condition at the engine wiring harness bracket where it is mounted at the transaxle case. In addition, a similar condition may also exist on the transaxle case near the same location, from a sharp edge formed during case casting, when equipped with manual transaxle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 2657 Correction: Refer to Illustrations for location of repairs. Repair Procedure: - Remove secondary ignition wire bracket and wires, set aside. - Remove clutch cable retainer and cables, set aside. (Manual transaxle only.) - Un-clip engine wiring harness conduit from retainer, pull back conduit to expose harness. - Using common "black" electrical tape (locally attained part), begin taping approximately 5 inches back from the point where the main harness breaks out into 3 smaller harnesses. - While taping to the break-out point, push the individual smaller conduits back and tape up the harnesses as far as possible. * IMPORTANT: Tape wire harness with 4 layers of tape to insure proper insulation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 914536D > Nov > 91 > Engine - Stalls/No Start/Runs Rough/Code 42 Set > Page 2658 * IMPORTANT: If any wires are worn through enough to short out against each other, if strands of wire are broken, or if an "open" wiring condition is found, refer to Section 8A of the applicable Service Manual for proper wiring repair. - Install wiring harness back into conduit. Before clipping retainer closed, pull the harness towards the center of the vehicle to remove any slack in the harness. This will keep the harness off the transaxle case and away from the transaxle controls. - Clip harness retainer into position. - Reinstall clutch cables and retainer. (Manual transaxle only). - Reinstall secondary ignition cables and bracket. Warranty and Labor Time Information: For taping and repositioning harness: Labor Code: T1789 Labor Time: 0.3 Hours For wiring repair, taping and repositioning of harness: Labor Code: T1789 Labor Time 0.4 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2659 Ignition Control Module: Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2660 Ignition Control Module: Description and Operation Coil Assembly The DIS module monitors the crank sensor signals and based on these signals sends a reference signal to the ECM so that correct spark and fuel injector control can be maintained during all driving conditions. During cranking, the DIS module monitors the "sync pulse" to begin the ignition firing sequence, and below 400 rpm the module controls spark advance by triggering each of the three coils at a pre-determined interval based on engine speed only. Above 400 rpm, the ECM controls the spark timing through the module (EST), and compensates for all driving conditions. The DIS module must receive a "sync pulse" and then a crank signal in that order to enable the engine to start. The DIS module is not repairable. When a module is replaced, the remaining DIS module components must be transferred to the new module. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2661 Ignition Control Module: Service and Repair Coil Assembly Remove or Disconnect 1. Negative battery cable. 2. DIS assembly from engine. 3. Coils from assembly. 4. Module from assembly plate. Install or Connect 1. Module to assembly plate. (Carefully engage sensor to module terminals.) 2. Coils. 3. DIS assembly to engine. 4. Negative battery cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications *** UPDATED BY TSB 90-168-6E, DATED FEBRUARY 1990 FUEL INJECTOR AND CRANKSHAFT SENSOR RESISTANCE VALUE Injector [1] ............................................................................................................................................ ................................... over 1.6 Ohms but not open. Crankshaft sensor ............................................. ........................................................................................................................ between 800 and 1200 Ohms [1] Check across injector terminals. THROTTLE POSITION SENSOR VOLTAGE Voltage [1]............................................................................................................................................ ........................................................... 0.33-1.33 volts NOTE: [1] The maximum TPS reading, at idle, is 1.33 volts. The TPS has an auto zeroing feature. If the voltage reading is within the range of about 0.33 to 1.33 volts, the ECM will use that value as closed throttle. If the voltage reading is out of the auto zero range at closed throttle, check for a binding throttle cable or damaged linkage. ECM CONTROLLED RELAYS AND SOLENOIDS Check the resistance of each ECM controlled relay or solenoid coil before replacing an ECM. Replace any relay or solenoid if the resistance measurement is less than 20 ohms. See ECM wiring diagrams under ELECTRICAL AND ELECTRONIC DIAGRAMS for coil terminal identification of solenoids and relays to be checked. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2667 Crankshaft Position Sensor: Mechanical Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2668 Rear Of Engine Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2669 Crankshaft Position Sensor: Description and Operation Typical DIS Crankshaft Sensor This crankshaft sensor is mounted remotely on the bottom side of the ignition module. This sensor protrudes into the block, within approximately 0.050" of the engine crankshaft reluctor. The reluctor is a special wheel cast into the crankshaft with seven slots cast into it, six of which are evenly spaced 60° apart. A seventh slot is spaced 10° from one of the other slots and serves to generate a "sync pulse." As the reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an induced voltage pulse. Based on the crank pulses, the DIS module sends reference signals to the ECM which are used to indicate crankshaft position and engine speed. The ignition module will continue to send these reference pulses to the ECM at a rate of one for each 180° or crankshaft rotation. The ECM will activate the fuel injector based on the recognition of every other reference pulse beginning at a crankshaft position of 120° after top dead center. By comparing the time between pulses, the DIS module can recognize the pulse representing the seventh slot or "sync pulse," which starts the calculation of the ignition coil sequence. The second crank pulse following the "sync pulse" signals the "DIS" module to fire the #2/3 ignition coil and the fifth crank pulse signals the module to fire the #1/4 ignition coil. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking Ignition Switch Lock Cylinder: Customer Interest Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 2679 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 2680 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 2681 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 2682 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 2683 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 2684 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 931943F > May > 93 > Ignition Lock Cylinder - Replacement Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Replacement Number: 93-194-3F Section: 3F Date: MAY 1993 Corporate Bulletin No.: 333207 ASE No.: A4 Subject: IGNITION LOCK CYLINDER REPLACEMENT Model and Year: 1991-93 CAVALIER SERVICE UPDATE When drilling out the ignition lock cylinder housing assembly shear bolts, care must be taken to remove the steering column from the car. Both the wiper switch and the turn signal switch must be removed before drilling the bolts out. There is a concern that metal shavings from the drilling of ignition lock cylinder shear bolts may enter the switches and cause the switch to become inoperative. The revised procedure below should be used. REMOVE 1. Steering wheel and covers (see Section 3F). 2. Steering column from vehicle (see Section 3F). 3. Turn signal switch from steering column (see Section 3F). 4. Wash/wipe switch from steering column (see Section 3F). IMPORTANT: Both the turn signal switch and wash/wipe switch have to be removed to prevent any metal shavings from entering the electrical components. 5. Lock cylinder housing assembly as follows: Put key in run position. - Drill off heads of two shear bolts using a 6.5 mm (1/4") drill bit. - Remove lock cylinder housing assembly. - Remove threaded ends of shear bolts from lock cylinder housing assembly with locking type pliers. - Clean all metal shavings from all parts after drilling. INSTALL 1. Lock cylinder housing assembly with two shear bolts. Key in run position. 2. Tighten two shear bolts until bolt head separates from bolt body approximately 11.0 N-m (97 lbs.in.) 3. Wash/wipe switch onto steering column (see Section 3F). 4. Turn signal switch onto steering column (see Section 3F). 5. Steering column into vehicle (see Section 3F). 6. Steering wheel and covers (see Section 3F). NOTE: Because the correct procedure must be followed when replacing ignition lock cylinders, Warranty will not be paid on turn signal or wiper/wash switches for 30 days after an ignition lock cylinder replacement. Use current labor time. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 2694 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 2695 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 2696 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 2697 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 2698 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 2699 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2705 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2706 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2707 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2713 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2714 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2715 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications TORQUE VALUES Crankshaft Sensor ............................................................................................................................... .................................................... 8 N-m (71 lbs in) DIS Assembly to Block .............................................................................................................................................................. 20-30 N-m (15-22 lbs ft) Spark Plugs ......................................................................................................................................... .......................................... 10-20 N-m (7-15 lbs ft) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Spark Plug - Torque Specification Update Spark Plug: Technical Service Bulletins Spark Plug - Torque Specification Update Number: 91-79-6A Section: 6A Date: October 1990 Corporate Bulletin No.: Subject: SPARK PLUG TORQUE SPECIFICATIONS Model and Year: 1990 CELEBRITY 1990-91 BERETTA, CORSICA CAMARO, CAVALIER AND LUMINA, 1990-91 U VAN (APV) TO: ALL CHEVROLET DEALERS When installing spark plugs in the 3.1L engine use the following revised specification in the Service Manuals listed below: Cast Iron or Aluminum Heads, 15 N-m (11 lbs.ft.) 1991 Lumina Pages 6D4 - 4, 5, 7 Cavalier Pages 6A3 - 19 Camaro Pages 6A2 - 31 Pages 6D4 - 7, 9 Corsica/Beretta Pages 6D4 - 3, 6 Pages 6A5 - 24 Lumina (APV) Pages 6A4 - 20, 46 and 6D4 - 6 1990 Celebrity Pages 6D4 - 3, 5 Lumina Pages 6D4 - 4, 5, 6 Cavalier Pages 6A3 - 19 Pages 6D4 - 3 Camaro Pages 6A2 - 30 Pages 6D4 - 7, 8 Corsica/Beretta Pages 6A5 - 20 Pages 6D4 - 2 Lumina (APV) Pages 6A4 - 17, 41 and 6D4 - 6 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Spark Plug - Torque Specification Update > Page 2723 Spark Plug: Technical Service Bulletins Spark Plugs - Revised Number: 93-03-6D Section: 6D Date: AUGUST 1992 Corporate Bulletin No.: 166001R ASE No.: Al, A6, A8 Subject: NEW DESIGN SPARK PLUGS Model and Yew: 1991-93 ALL PASSENGER CARS AND TRUCKS WITH GASOLINE ENGINES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO., 91-234A-OB, DATED JULY 1992. THE 1992 AND 1993 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 91-234A-OB SHOULD BE DISCARDED. In 1991 GM introduced a new design spark plug for use in all trucks equipped with gas engines. These new design spark plugs have a ceramic insulator which is approximately 1/8 inch longer than the insulator used in previous model years. The longer length spark plugs, which conform to S.A.E. and I.S.O. Engineering guidelines, magnify the problem of cracked insulators because currently, most spark plug sockets are not of sufficient length to properly engage the shell hex. If the spark plug shell hex is not fully engaged in the spark plug socket wrench, the socket may cock at an angle and cause insulator cracking and/or breakage during plug installation or removal. When servicing these new design spark plugs, make sure that the spark plug socket being used is deep enough to accommodate the longer length insulator. The spark plug socket wrench should conform to the proposed S.A.E. and I.S.O. world standards for spark plug socket wrenches. Spark plug socket wrenches that conform to these standards are designed to accept the lengthened spark plugs and allow full engagement of the hex nut on the shell of the spark plug. Use of a spark plug socket which is NOT deep enough may result in the ceramic insulator becoming cracked above the spark plug shell. Note: SOME CRACKS IN THE INSULATOR M" NOT BE VISIBLE. SUCH CRACKS MAY LATER CAUSE A SPARK PLUG TO MISFIRE. SPARK PLUG MISFIRES ARE OFTEN MISDIAGNOSED AS A SLIPPING TRANSMISSION, DEFECTIVE TORQUE CONVERTER CLUTCH, ENGINE IMBALANCE, OR MALFUNCTIONING FUEL SYSTEM. To prevent insulator damage, it is recommended that the proper spark plug socket wrench be used when removing or replacing spark plugs. One such spark plug socket is the Kent-Moore J-39358 spark plug socket. The tool is available from Kent-Moore. For ordering information call 1 -800-345-2233 or write: Kent-Moore SPX Corporation 39784 Little Mack Roseville, MI 48066-2298 Fax: 313-774-9870 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 2724 Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ................................................... 0.90 mm (035 in.) Spark Plug Torque ............................................. ......................................................................................................................... 10 - 20 Nm (7 - 15 ft lb) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Specifications Shift Solenoid: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Solenoid To Valve Body ....................................... .............................................................................................................................................................. .8 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 Cover, Auxiliary Valve Body And Pump 3T40 (125C) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 2734 Torque Converter Clutch Solenoid: Description and Operation The purpose of the Transmission Converter Clutch (TCC) feature is to eliminate the power loss of the torque converter stage when the vehicle is in a cruise mode. The TCC System uses a solenoid operated valve to couple the engine flywheel to the output shaft of the transmission through the torque converter. Lockup reduces slippage in the converter increasing fuel economy. For the converter clutch to apply, two conditions must be met: 1. Internal transmission fluid pressure must be correct. 2. The ECM must complete a ground circuit to energize the TCC solenoid which moves a check ball in the fluid line. This allows the converter clutch to apply, when hydraulic pressure is correct. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Service and Repair > Torque Converter Clutch (TCC) Solenoid Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch (TCC) Solenoid TORQUE CONVERTER CLUTCH (TCC) SOLENOID & SWITCHES 3T40 (125C) Auxiliary Valve Body, Valve Body And Oil Pump Assembly Torque Converter Clutch Solenoid & Switches REMOVE OR DISCONNECT 1. Negative battery cable. 2. Raise vehicle and suitably support. 3. Drain fluid. 4. Left front tire and wheel assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 2737 5. Valve body cover. Refer to "Valve Body Cover". 6. Wiring harness from case electrical connector and leads from 3rd clutch pressure switch. 7. Torque converter clutch bolt to auxiliary valve body. 8. 3rd clutch pressure switch. 9. Second clutch switch, if applicable. INSTALL OR CONNECT 1. Second clutch switch, if applicable. TIGHTEN ^ Switch to 11 Nm (8 lb. ft.). 2. 3rd clutch pressure switch. TIGHTEN ^ Switch to 11 Nm (8 lb. ft.). 3. Torque converter clutch bolt to auxiliary valve body. Install new O-ring. TIGHTEN ^ Bolt to 11 Nm (8 lb. ft.). 4. Wire harness to case and switches. 5. Valve body cover with a new gasket. Refer to "Valve Body Cover". 6. Lower vehicle. 7. Negative battery cable. ADJUST ^ T.V. cable. ^ Fluid level. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 2738 Torque Converter Clutch Solenoid: Service and Repair Valve Body Cover VALVE BODY COVER 3T40 (125C) Side Cover And Control Valve View REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Drain oil. 3. Left front tire and wheel assembly. 4. Left splash shield. 5. Valve body cover to transaxle bolts. INSPECT ^ Bolts INSTALL OR CONNECT 1. Valve body cover with a new gasket and bolts. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 2739 Valve Body Cover NOTE: It is necessary to use GM thread locker (P/N 12345382) or equivalent non-locking sealant to reduce the potential for fluid leaks on the indicated bolts. 2. Left splash shield. 3. Left front tire and wheel assembly. 4. Lower vehicle. ADJUST ^ Oil level. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > Customer Interest: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned A/T Shift Indicator Module: Customer Interest A/T - Shift Indicator Misaligned Number: 91-458-7A Section: 7A Date: DEC. 1991 Corporate Bulletin No.: 138305 ASE No.: A2 Subject: SHIFT INDICATOR MISALIGNED Model and Year: 1991 CAVALIER WITH AUTOMATIC TRANSMISSION Condition: Shift indicator may come out of adjustment. Cause: Adjuster did not "collapse" on indicator tape during production, thus creating a low ratcheting effort. Correction: Replace console trim plate with updated part. Refer to "Parts Information" for updated part number. Refer to Section 8C for replacement procedure. Parts Information: 22575236 Trim plate assembly - with power windows 22575237 Trim plate assembly - without power windows Parts are currently available from GMSPO. Warranty Information: Labor Operation Number: K5100 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned A/T Shift Indicator Module: All Technical Service Bulletins A/T - Shift Indicator Misaligned Number: 91-458-7A Section: 7A Date: DEC. 1991 Corporate Bulletin No.: 138305 ASE No.: A2 Subject: SHIFT INDICATOR MISALIGNED Model and Year: 1991 CAVALIER WITH AUTOMATIC TRANSMISSION Condition: Shift indicator may come out of adjustment. Cause: Adjuster did not "collapse" on indicator tape during production, thus creating a low ratcheting effort. Correction: Replace console trim plate with updated part. Refer to "Parts Information" for updated part number. Refer to Section 8C for replacement procedure. Parts Information: 22575236 Trim plate assembly - with power windows 22575237 Trim plate assembly - without power windows Parts are currently available from GMSPO. Warranty Information: Labor Operation Number: K5100 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for A/T Shift Indicator Module: > 331052 > Oct > 93 > Seat Belts - Install Rear Seat Child Comfort Guides Seat Belt: All Technical Service Bulletins Seat Belts - Install Rear Seat Child Comfort Guides Group Ref.: Body Bulletin No.: 331052 Date: October, 1993 SUBJECT: IMPROVED COMFORT FOR SMALL REAR SEAT OCCUPANTS AND CHILDREN USING SHOULDER BELTS (INSTALL REAR SEAT CHILD COMFORT GUIDES) MODELS: 1989-93 BUICK SKYLARK 1989-93 CHEVROLET CAVALIER (EXCLUDING CONVERTIBLE) 1988-93 CHEVROLET CORSICA/BERETTA 1992-93 OLDSMOBILE ACHIEVA 1989-91 OLDSMOBILE CALAIS 1989-93 PONTIAC GRAND AM 1989-93 PONTIAC SUNBIRD (EXCLUDING CONVERTIBLE) Condition: Some owners of the above vehicles may comment on the rear seat shoulder belts resting on the neck of one or both of the rear seat passengers, particulary those of small adults or children. Correction: This condition can be corrected by installing rear seat child comfort guides on the vehicle. 1. Remove the rear seat cushion and seat back. Refer to the procedures in Section 10-10 of the appropriate Service Manual. 2. Cut out the appropriate template that is included with the guide kit. 3. Position the template on the plastic quarter trim panel as shown in the information included in the guide kit. 4. Carefully drill a 1/4" hole through the quarter trim panel only. 5. Position the rear seat shoulder belt guide assembly to the previously drilled hole and snap the fastener into place. 6. Follow steps 3-5 for the opposite side of the vehicle. 7. Install the rear seat cushion and seat back. Refer to the procedures in Section 10-10 of the appropriate Service Manual. Parts Information: Parts are currently available from GMSPO. For vehicles repaired under warranty, use: Labor Operation Number: T3386 Labor Time: .5 hr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for A/T Shift Indicator Module: > NHTSA92V003000 > Jan > 92 > Recall 92V003000: Seat Belt Guide Loops Defect Seat Belt: All Technical Service Bulletins Recall 92V003000: Seat Belt Guide Loops Defect THE FRONT DOOR SHOULDER BELT GUIDE LOOPS MAY BE CRACKED AND ARE NOT IN COMPLIANCE WITH FMVSS 208. THE SEAT OCCUPANT FACES INCREASED RISK OF INJURY IN THE EVENT OF A SUDDEN STOP OR ACCIDENT. INSTALL REINFORCING PLATES ON THE CRACKED SHOULDER BELT GUIDES. SYSTEM: SAFETY BELTS; FMVSS 208. DESCRIPTION OF VEHICLES: PASSENGER VEHICLES; 1991 GM "J" AND "W" MODEL CARS. 1991 BUICK REGAL 1991 CHEVROLET CAVALIER 1991 CHEVROLET LUMINA 1991 OLDSMOBILE CUTLASS 1991 PONTIAC GRAND PRIX 1991 PONTIAC SUNBIRD Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Specifications Fluid Pressure Sensor/Switch: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Pressure Switch ................................................................................................................................... ................................................................................. 8 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations Transmission Position Switch/Sensor: Locations Rear Of 3.1L Rear Of Engine, Top LH Side Of Transaxle Applicable to: 1L/V6-192 Engine. Cavalier w/Automatic Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 2782 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch & Connector The PARK/NEUTRAL switch indicates to the computer when the transmission is in park or neutral. This information is used by the computer for ignition timing, Idle Air Control (IAC), and Transmission Torque Converter Clutch (TCC) operation. DO NOT drive the vehicle with the PARK/NEUTRAL switch disconnected, since idle quality may be affected. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 2783 Transmission Position Switch/Sensor: Testing and Inspection Chart C-1A Wiring Diagram For P/N Switch CIRCUIT DESCRIPTION: The PARK/NEUTRAL switch contacts are closed to ground in park or neutral and open in drive ranges. The ECM supplies ignition voltage through a current limiting resistor to circuit 434, and senses a closed switch when the voltage on circuit 434 drops to less than one volt. The ECM uses the P/N signal as one of the inputs to control idle air and vehicle speed sensor diagnostics. TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 2784 1. Checks for a closed switch to ground in the PARK position. Different makes of "Scan" tools will read PARK/NEUTRAL differently. Refer to operators manual for type of display used for a specific tool. 2. Checks for an open switch in drive range. 3. Be sure the "Scan" tool indicates drive even while wiggling the shifter to test for an intermittent or misadjusted switch in drive. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 2785 Transmission Position Switch/Sensor: Adjustments 1. Place transaxle shift lever in NEUTRAL. 2. Loosen switch attaching screws. 3. Rotate switch on shaft assembly to align service adjustment hole with carrier tang hole. a. Insert 2.34 mm (3/32 inch) maximum diameter gauge pin to a depth of 15.0 mm (5/8 inch). 4. Tighten attaching screws. See SPECIFICATIONS/MECHANICAL for torque values. 5. Remove the gauge pin. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 2786 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Start and Backup Lamp Switch 1. Remove negative battery cable, shift linkage, electrical connector, mounting bolts, and switch assembly. 2. Replacement using old or new switch. a. Place shift shaft in NEUTRAL. b. Align flats of shift shaft with switch. c. Old Switch only - Install mounting bolts-to-case, loosely. Insert gauge pin in service adjustment hole, and rotate switch until pin drops into a depth of 9.0 mm (9/64") and tighten bolts (see SPECIFICATIONS/MECHANICAL for torque values). d. New Switch only - Install mounting bolts and tighten. If bolt holes do not align with mounting boss on transaxle, verify that the shift shaft is in NEUTRAL; DO NOT rotate the switch. The switch is pinned in the NEUTRAL position. NOTE: If the switch has been rotated and the pin is broken, the switch can be adjusted using the old switch procedure and ADJUSTMENT PROCEDURES. 3. See ADJUSTMENT PROCEDURES for PARK/NEUTRAL switch adjustment. 4. After the switch is installed, verify that the engine will start only in PARK (A/T) or NEUTRAL (M/T). If the engine starts in any other position, readjust the switch using old switch procedure and ADJUSTMENT PROCEDURES. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Specifications Transmission Speed Sensor: Specifications Electronic Speed Sensor Retainer ...................................................................................................... ...................................................................... 7 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 915147B > Sep > 92 > Engine - Surge On Deceleration PROM - Programmable Read Only Memory: Customer Interest Engine - Surge On Deceleration Number: 91-514-7B Section: 7B Date: SEPT. 1992 Corporate Bulletin No.: 236514 ASE No.: A3 Subject: ENGINE SURGE ON DECELERATION Model and Year: 1990-91 CORSICA, BERETTA AND CAVALIER WITH 2.2L ENGINE AND MANUAL TRANSMISSION CONDITION Some owners of 1991-90 "J" and "L'cars with the 2.2L LM3 engine (VIN Code G), and a manual transmission may comment of an engine surge during deceleration. CAUSE Spark is advanced in order to control possible engine pop-backs. This spark allows the engine to surge on deceleration. CORRECTION Install a new prom package from the table (see illustration). Parts are currently available from GMSPO. Labor Operation Number: T0500 Labor Time: 0.4 Hour "J" Car 0.5 Hour "L:'Car Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 914736E > Jan > 92 > Engine - Chuggle at Low Speeds PROM - Programmable Read Only Memory: Customer Interest Engine - Chuggle at Low Speeds Number: 91-473-6E Section: 6E Date: JAN. 1992 Corporate Bulletin No.: 136008 ASE No.: A1, A8 Subject: ENGINE CHUGGLE AT LOW SPEEDS Model and Year: 1990-91 CAVALIER, CORSICA AND BERETTA WITH 2.2L ENGINE AND AUTOMATIC TRANSMISSION Condition: Some owners of 1990 and 1991 J and L cars with 2.2L engines may comment of an engine shudder or chuggle condition when driving at slow speeds in high gear. Cause: Torque converter clutch locking up at slow speeds during some driving conditions. Correction: A new PROM package has been released which raises the torque converter clutch lockup speed from 23 MPH to 35 MPH. Car Eng Trans Emissions PROM Pkg Broadcast Scanner Body Type Type Type P/N Code I.D. J 2.2L AUTO FEDERAL 16173383 BABH 3371 J 2.2L AUTO CALIF. 16173384 BABJ 3381 L 2.2L AUTO FEDERAL 16173385 BABK 3391 L 2.2L AUTO CALIF. 16173386 BABL 3401 Parts are expected to be available on January 13, 1992. In case of limited inventory, parts will be placed on 400 Control to waive VIP surcharges. Only verifiable emergency VIP orders will be accepted. SPO will make every effort to obtain parts. However, the part will be shipped premium transportation at dealer's expense and all other order types will be placed on backorder until the 400 control is removed. Labor Operation Number: T0500 Labor Time: .4 Hours "J" Car .5 Hours "L" Car Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 912226E > Mar > 91 > Engine - Cold Acceleration Hesitation or Stall PROM - Programmable Read Only Memory: Customer Interest Engine - Cold Acceleration Hesitation or Stall Number: 91-222-6E Section: 6E Date: March 1991 Corporate Bulletin No.: 136502 Subject: HESITATION OR STALL ON COLD ACCELERATION Model and Year: 1990-91 CAVALIER, CORSICA, BERETTA WITH 2.2L ENGINE AND 3T40 AUTOMATIC TRANSMISSION Condition: Some owners of 1990 and 1991 J and L cars with 2.2L engines may comment of an engine hesitation or stall during a cold acceleration. Cause: Low volatility fuel that does not fully vaporize in a cold intake manifold. Correction: New PROM packages have been released which compensate for low volatility fuel during cold acceleration. Install the correct PROM package based on the chart below, and recommend that the owner use low octane fuel (87 or equivalent). Vehicles Affected: Body Model Emissions Assembly Vehicles Style Year Type Plant Affected J 1990 Federal Janesville All Lordstown All Calif. Janesville All Lordstown All 1991 Federal Janesville All Lordstown VIN Prior to M7173516 Calif. Janesville ALL Lordstown VIN Prior to M7173032 L 1990 Federal Linden All Wilmington All Calif. Linden All Wilmington All 1991 Federal Linden VIN Prior to ME1 42136 Wilmington VIN Prior to MY159347 Calif. Linden VIN Prior to ME142841 Wilmington VIN Prior to MY159089 PROM Applications: Body Emissions Broadcast Scanner PROM Part Style Type Code I.D. Number J Federal AWWM 8321 16158344 Calif. AWWN 8331 16158349 L Federal AWWP 8341 16158354 Calif. AWWR 8351 16158358 Parts are currehtly available from GMSPO. Labor Operation Number: T0500 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 912226E > Mar > 91 > Engine - Cold Acceleration Hesitation or Stall > Page 2806 Labor Hours: 0.4 Hours Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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: > 99-06-04-053 > Nov > 99 > PROM - Powertrain Control Module Reprogramming PROM - Programmable Read Only Memory: All Technical Service Bulletins PROM - Powertrain Control Module Reprogramming File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-053 Date: November, 1999 INFORMATION Subject: Powertrain Control Module (PCM) Reprogramming (Do Not Reprogram Using the Same Download Files as Those Already Present in The Control Module) Models: 1990-2000 Passenger Cars and Trucks with Reprogrammable PCM It is strongly recommended to NOT reinstall the same software and/or calibration download file(s) into the powertrain control module as those that are already present in the PCM. There is no technical reason that the download files inside the PCM would ever become corrupted after the control module had previously been successfully programmed. A P0601 (Control Module Read Only Memory) Diagnostic Trouble Code would set in memory and the MIL would be illuminated if the controller memory became corrupted. The Techline Information System 2000 (TIS 2000) PC, combined with vehicle information gained through the Tech 2, can determine when an attempt to reprogram a PCM using the same download files (as those already in the control module) is being requested. If this is attempted, the TIS 2000 PC currently displays the following message: Notice: THE CALIBRATION SELECTED IS THE CURRENT CALIBRATION IN THE CONTROL MODULE. PROGRAMMING WITH THE SAME DOWNLOAD FILES IS NOT AN EFFECTIVE REPAIR. SELECT ( YES ) TO CONTINUE PROGRAMMING THE CONTROL MODULE,OR ( NO ) TO CANCEL. Effective in the first quarter of 2000, the TIS 2000 PC will indicate: Important: THE CALIBRATION SELECTED IS ALREADY THE CURRENT CALIBRATION IN THE CONTROL MODULE. REPROGRAMMING WITH THE SAME DOWNLOAD FILE IS NOT ALLOWED. Certain learned values, such as: (but not limited to) ^ fuel trim (previously known as block learn memory), ^ IAC learned position in various park/neutral and air conditioning on/off combinations, ^ certain OBDII diagnostic thresholds, ^ automatic transmission shift adapts will revert back to their unlearned starting point values after a reprogramming event occurs. It is feasible that the engine or transmission might temporarily operate differently after a reprogramming event, until these values are re-learned. Relearning occurs while operating the vehicle through normal driving routines. If the same download files are simply reinstalled, any changes noticed in engine operation will likely disappear in a short amount of time and/or driving distance. Reprogramming the control module with the same download files that already exist in the module will only accomplish a warranty claim for a non-effective repair, and a likely comeback. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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: > 915147B > Sep > 92 > Engine - Surge On Deceleration PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Surge On Deceleration Number: 91-514-7B Section: 7B Date: SEPT. 1992 Corporate Bulletin No.: 236514 ASE No.: A3 Subject: ENGINE SURGE ON DECELERATION Model and Year: 1990-91 CORSICA, BERETTA AND CAVALIER WITH 2.2L ENGINE AND MANUAL TRANSMISSION CONDITION Some owners of 1991-90 "J" and "L'cars with the 2.2L LM3 engine (VIN Code G), and a manual transmission may comment of an engine surge during deceleration. CAUSE Spark is advanced in order to control possible engine pop-backs. This spark allows the engine to surge on deceleration. CORRECTION Install a new prom package from the table (see illustration). Parts are currently available from GMSPO. Labor Operation Number: T0500 Labor Time: 0.4 Hour "J" Car 0.5 Hour "L:'Car Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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: > 914736E > Jan > 92 > Engine - Chuggle at Low Speeds PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Chuggle at Low Speeds Number: 91-473-6E Section: 6E Date: JAN. 1992 Corporate Bulletin No.: 136008 ASE No.: A1, A8 Subject: ENGINE CHUGGLE AT LOW SPEEDS Model and Year: 1990-91 CAVALIER, CORSICA AND BERETTA WITH 2.2L ENGINE AND AUTOMATIC TRANSMISSION Condition: Some owners of 1990 and 1991 J and L cars with 2.2L engines may comment of an engine shudder or chuggle condition when driving at slow speeds in high gear. Cause: Torque converter clutch locking up at slow speeds during some driving conditions. Correction: A new PROM package has been released which raises the torque converter clutch lockup speed from 23 MPH to 35 MPH. Car Eng Trans Emissions PROM Pkg Broadcast Scanner Body Type Type Type P/N Code I.D. J 2.2L AUTO FEDERAL 16173383 BABH 3371 J 2.2L AUTO CALIF. 16173384 BABJ 3381 L 2.2L AUTO FEDERAL 16173385 BABK 3391 L 2.2L AUTO CALIF. 16173386 BABL 3401 Parts are expected to be available on January 13, 1992. In case of limited inventory, parts will be placed on 400 Control to waive VIP surcharges. Only verifiable emergency VIP orders will be accepted. SPO will make every effort to obtain parts. However, the part will be shipped premium transportation at dealer's expense and all other order types will be placed on backorder until the 400 control is removed. Labor Operation Number: T0500 Labor Time: .4 Hours "J" Car .5 Hours "L" Car Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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: > 913186E > May > 91 > ECM/PCM - Damage Prevention PROM - Programmable Read Only Memory: All Technical Service Bulletins ECM/PCM - Damage Prevention Number: 91-318-6E Section: 6E Date: MAY 1991 Corp. Bulletin No.: 176502R Subject: DAMAGE TO ECM/PCM CIRCUIT BOARD WHEN INSTALLING A MEM-CAL Model and Year: 1986-91 ALL PASSENGER CARS AND TRUCKS CONDITION: When installing a service replacement ECM/PCM, the use of incorrect MEMCAL installation procedures may cause the ECM/PCM to fail before it can be installed in the vehicle. This condition may appear as if the ECM/PCM were defective when it was shipped to the dealership, when in fact it was damaged while being installed. In addition this condition may also occur when installing an "updated" service MEM-CAL into the vehicles original equipment ECM/PCM. CAUSE: Excessive vertical force may be applied to the MEM-CAL resulting in flexing of the circuit board and damage to the connections between the circuit board and attached components. Excessive verticle force may be generated in two ways. 1. Incorrect MEM-CAL installation procedure. 2. Interference between MEM-CAL and cover. CORRECTION: Use the following procedure. Service Procedure: Important: This procedure supersedes any instructions regarding MEM-CAL installation dated prior to September 1990. 1. Inspect the MEM-CAL to determine if a cork spacer is glued to the top side of the MEM-CAL assembly. If so, remove it prior to installation. 2. Align small notches with matching notches in the ECM/PCM MEM-CAL socket. 3. VERY GENTLY press down on the ends of the MEM-CAL until the locking levers are rotated toward the sides of the MEM-CAL. Notice: To avoid ECM/PCM damage, do not press on the ends of the MEM-CAL until the levers snap into place. Do not use any vertical force beyond the minimum required to engage the MEM-CAL into its socket. 4. While continuing light pressure on the ends of MEM-CAL, use your index fingers to press the locking levers inward until they are snapped into place. Listen for click. 5. Install MEM-CAL cover and install ECM/PCM in vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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: > 912226E > Mar > 91 > Engine - Cold Acceleration Hesitation or Stall PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Cold Acceleration Hesitation or Stall Number: 91-222-6E Section: 6E Date: March 1991 Corporate Bulletin No.: 136502 Subject: HESITATION OR STALL ON COLD ACCELERATION Model and Year: 1990-91 CAVALIER, CORSICA, BERETTA WITH 2.2L ENGINE AND 3T40 AUTOMATIC TRANSMISSION Condition: Some owners of 1990 and 1991 J and L cars with 2.2L engines may comment of an engine hesitation or stall during a cold acceleration. Cause: Low volatility fuel that does not fully vaporize in a cold intake manifold. Correction: New PROM packages have been released which compensate for low volatility fuel during cold acceleration. Install the correct PROM package based on the chart below, and recommend that the owner use low octane fuel (87 or equivalent). Vehicles Affected: Body Model Emissions Assembly Vehicles Style Year Type Plant Affected J 1990 Federal Janesville All Lordstown All Calif. Janesville All Lordstown All 1991 Federal Janesville All Lordstown VIN Prior to M7173516 Calif. Janesville ALL Lordstown VIN Prior to M7173032 L 1990 Federal Linden All Wilmington All Calif. Linden All Wilmington All 1991 Federal Linden VIN Prior to ME1 42136 Wilmington VIN Prior to MY159347 Calif. Linden VIN Prior to ME142841 Wilmington VIN Prior to MY159089 PROM Applications: Body Emissions Broadcast Scanner PROM Part Style Type Code I.D. Number J Federal AWWM 8321 16158344 Calif. AWWN 8331 16158349 L Federal AWWP 8341 16158354 Calif. AWWR 8351 16158358 Parts are currehtly available from GMSPO. Labor Operation Number: T0500 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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: > 912226E > Mar > 91 > Engine - Cold Acceleration Hesitation or Stall > Page 2828 Labor Hours: 0.4 Hours Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 99-06-04-053 > Nov > 99 > PROM - Powertrain Control Module Reprogramming PROM - Programmable Read Only Memory: All Technical Service Bulletins PROM - Powertrain Control Module Reprogramming File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-04-053 Date: November, 1999 INFORMATION Subject: Powertrain Control Module (PCM) Reprogramming (Do Not Reprogram Using the Same Download Files as Those Already Present in The Control Module) Models: 1990-2000 Passenger Cars and Trucks with Reprogrammable PCM It is strongly recommended to NOT reinstall the same software and/or calibration download file(s) into the powertrain control module as those that are already present in the PCM. There is no technical reason that the download files inside the PCM would ever become corrupted after the control module had previously been successfully programmed. A P0601 (Control Module Read Only Memory) Diagnostic Trouble Code would set in memory and the MIL would be illuminated if the controller memory became corrupted. The Techline Information System 2000 (TIS 2000) PC, combined with vehicle information gained through the Tech 2, can determine when an attempt to reprogram a PCM using the same download files (as those already in the control module) is being requested. If this is attempted, the TIS 2000 PC currently displays the following message: Notice: THE CALIBRATION SELECTED IS THE CURRENT CALIBRATION IN THE CONTROL MODULE. PROGRAMMING WITH THE SAME DOWNLOAD FILES IS NOT AN EFFECTIVE REPAIR. SELECT ( YES ) TO CONTINUE PROGRAMMING THE CONTROL MODULE,OR ( NO ) TO CANCEL. Effective in the first quarter of 2000, the TIS 2000 PC will indicate: Important: THE CALIBRATION SELECTED IS ALREADY THE CURRENT CALIBRATION IN THE CONTROL MODULE. REPROGRAMMING WITH THE SAME DOWNLOAD FILE IS NOT ALLOWED. Certain learned values, such as: (but not limited to) ^ fuel trim (previously known as block learn memory), ^ IAC learned position in various park/neutral and air conditioning on/off combinations, ^ certain OBDII diagnostic thresholds, ^ automatic transmission shift adapts will revert back to their unlearned starting point values after a reprogramming event occurs. It is feasible that the engine or transmission might temporarily operate differently after a reprogramming event, until these values are re-learned. Relearning occurs while operating the vehicle through normal driving routines. If the same download files are simply reinstalled, any changes noticed in engine operation will likely disappear in a short amount of time and/or driving distance. Reprogramming the control module with the same download files that already exist in the module will only accomplish a warranty claim for a non-effective repair, and a likely comeback. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 913186E > May > 91 > ECM/PCM - Damage Prevention PROM - Programmable Read Only Memory: All Technical Service Bulletins ECM/PCM - Damage Prevention Number: 91-318-6E Section: 6E Date: MAY 1991 Corp. Bulletin No.: 176502R Subject: DAMAGE TO ECM/PCM CIRCUIT BOARD WHEN INSTALLING A MEM-CAL Model and Year: 1986-91 ALL PASSENGER CARS AND TRUCKS CONDITION: When installing a service replacement ECM/PCM, the use of incorrect MEMCAL installation procedures may cause the ECM/PCM to fail before it can be installed in the vehicle. This condition may appear as if the ECM/PCM were defective when it was shipped to the dealership, when in fact it was damaged while being installed. In addition this condition may also occur when installing an "updated" service MEM-CAL into the vehicles original equipment ECM/PCM. CAUSE: Excessive vertical force may be applied to the MEM-CAL resulting in flexing of the circuit board and damage to the connections between the circuit board and attached components. Excessive verticle force may be generated in two ways. 1. Incorrect MEM-CAL installation procedure. 2. Interference between MEM-CAL and cover. CORRECTION: Use the following procedure. Service Procedure: Important: This procedure supersedes any instructions regarding MEM-CAL installation dated prior to September 1990. 1. Inspect the MEM-CAL to determine if a cork spacer is glued to the top side of the MEM-CAL assembly. If so, remove it prior to installation. 2. Align small notches with matching notches in the ECM/PCM MEM-CAL socket. 3. VERY GENTLY press down on the ends of the MEM-CAL until the locking levers are rotated toward the sides of the MEM-CAL. Notice: To avoid ECM/PCM damage, do not press on the ends of the MEM-CAL until the levers snap into place. Do not use any vertical force beyond the minimum required to engage the MEM-CAL into its socket. 4. While continuing light pressure on the ends of MEM-CAL, use your index fingers to press the locking levers inward until they are snapped into place. Listen for click. 5. Install MEM-CAL cover and install ECM/PCM in vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Page 2838 PROM - Programmable Read Only Memory: Service Precautions A PROM is a sensitive electronic part and must be handled with care. If the connector terminals (pins) on the bottom of the PROM are exposed, avoid touching them. Pins can be broken easily, and the PROM can be damaged by static electric discharge. Follow these guidelines when replacing a PROM: ^ Disconnect the battery ground cable before removing a PROM. Reconnect the cable after the new PROM is installed. ^ DO NOT try to remove a PROM from its plastic PROM carrier. ^ Note the direction in which the original PROM and its carrier were installed in the ECM, and install the replacement PROM in the same direction. Most PROM's are marked with a notch at one end for orientation. Many PROM's can be installed in a reversed direction, which will destroy the PROM when power is applied. CAUTION: A PROM can be damaged by static electric discharge. Avoid damage as follows: ^ DO NOT remove a PROM from its packing material until you are ready to install it. DO NOT hold a PROM by its pins. ^ Before entering a vehicle to remove or replace a PROM, touch an exposed metal part of the vehicle to discharge any static charge from your body or use anti-static wrist straps. ^ Avoid sliding across upholstery or carpeting when removing or installing a PROM. If this is not possible, touch an exposed metal part of the vehicle with your free hand before removing a PROM or installing a new one in its socket in the ECM. ^ When available, use an antistatic grounding strap attached to your wrist and clipped to a metal part of the vehicle body to prevent static charges from accumulating. Antistatic, conductive floormats are also available. ^ For some vehicles, it may be desirable to remove the ECM when replacing the PROM. ^ NOTE: See POWERTRAIN MANAGEMENT / SERVICE PRECAUTIONS / VEHICLE DAMAGE WARNINGS / ELECTRICAL PRECAUTIONS Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Introducing the GM PROM Cross Reference Index PROM - Programmable Read Only Memory: Application and ID Introducing the GM PROM Cross Reference Index This PROM cross reference index provides tables that let you use a PROM identification (ID) code to identify the PROM installed in the engine control module (ECM) on most GM vehicles. The code can be either - or both - the internal "scan ID" code or the external PROM code. From the PROM identification, you can find the part number of the PROM and trace the PROM history to determine if any revised PROM's have been issued to supersede the one in the vehicle. The PROM history for a specific vehicle lists a succession of superseding PROM's ending with the most recent PROM released as a service part for the vehicle. PROM's that were released as service parts and explained in a technical service bulletin (TSB) are listed with a description of why the PROM was issued. In most cases, the applicable TSB also is referenced. This index lists ECM PROM's for the 1980-95 vehicles. It does not contain ID codes and part numbers for all PROM's used in all GM vehicles. NOTE: GM flash PROM's (EEPROM's) can only be updated at GM Dealerships with factory-supplied equipment. These cars will not display a PROM ID. By following the steps outlined below, you can use the PROM index to determine if the problem you are diagnosing can possibly be corrected by installing a revised PROM. The PROM index tables are organized by model year, engine displacement, and engine code (the eighth digit of the Vehicle Identification Number). The table columns are arranged as shown below: Example of Table Column Arrangement SCAN PROM PROM PART SUPERSEDING TSB REFERENCE ID CODE (BCC) NUMBER ID PART NUMBER NUMBER (1) (2) (3) (4) (5) .............................................................................................................................................................. ........................................................................ 9461 8958 AMU 16058955R 8290 01228290 86194 Column 1, SCAN ID: The scan ID is the internal PROM identification number transmitted on the ECM data stream and displayed by the scanner as PROM ID. The PROM records for each year and engine are listed numerically by this scan ID. Column 2, PROM CODE: These are the numbers and letters marked on the top of the PROM itself. The numbers are often referred to as the "external PROM ID." The letters are often called the "broadcast code." Together they are the external PROM code. Column 3, PROM P/N: This is the GM part number for the PROM identified by the codes in columns 1 and 2. Column 4, SUPERSEDING ID PROM PART NUMBER: Use the superseding scan ID to locate the newer PROM in the table. If the scan ID for the superseding PROM is not known, the PROM broadcast code is listed here. If the PROM is superseded by a newer PROM, that part number is listed here. Column 5, TSB REFERENCE NUMBER The TSB NUMBER column identifies the original TSB that released this PROM for service. Whenever possible you should refer to the TSB for additional information before changing a PROM. The bulletin may list other parts that must be installed when the PROM is changed, or it may provide additional troubleshooting information. To find a TSB, see Reading Technical Service Bulletins. See: Reading Technical Service Bulletins This will display all the TSB's for that particular vehicle. EXPANDED FOOTNOTES Here you will find SUPERSEDING SCAN ID, PROM PART NUMBERS, symptoms and additional parts that need to be replaced when servicing the PROM. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Introducing the GM PROM Cross Reference Index > Page 2841 PROM - Programmable Read Only Memory: Application and ID Introducing the GM PROM Cross Reference Index This PROM cross reference index provides tables that let you use a PROM identification (ID) code to identify the PROM installed in the engine control module (ECM) on most GM vehicles. The code can be either - or both - the internal "scan ID" code or the external PROM code. From the PROM identification, you can find the part number of the PROM and trace the PROM history to determine if any revised PROM's have been issued to supersede the one in the vehicle. The PROM history for a specific vehicle lists a succession of superseding PROM's ending with the most recent PROM released as a service part for the vehicle. PROM's that were released as service parts and explained in a technical service bulletin (TSB) are listed with a description of why the PROM was issued. In most cases, the applicable TSB also is referenced. This index lists ECM PROM's for the 1980-95 vehicles. It does not contain ID codes and part numbers for all PROM's used in all GM vehicles. NOTE: GM flash PROM's (EEPROM's) can only be updated at GM Dealerships with factory-supplied equipment. These cars will not display a PROM ID. By following the steps outlined below, you can use the PROM index to determine if the problem you are diagnosing can possibly be corrected by installing a revised PROM. The PROM index tables are organized by model year, engine displacement, and engine code (the eighth digit of the Vehicle Identification Number). The table columns are arranged as shown below: Example of Table Column Arrangement SCAN PROM PROM PART SUPERSEDING TSB REFERENCE ID CODE (BCC) NUMBER ID PART NUMBER NUMBER (1) (2) (3) (4) (5) .............................................................................................................................................................. ........................................................................ 9461 8958 AMU 16058955R 8290 01228290 86194 Column 1, SCAN ID: The scan ID is the internal PROM identification number transmitted on the ECM data stream and displayed by the scanner as PROM ID. The PROM records for each year and engine are listed numerically by this scan ID. Column 2, PROM CODE: These are the numbers and letters marked on the top of the PROM itself. The numbers are often referred to as the "external PROM ID." The letters are often called the "broadcast code." Together they are the external PROM code. Column 3, PROM P/N: This is the GM part number for the PROM identified by the codes in columns 1 and 2. Column 4, SUPERSEDING ID PROM PART NUMBER: Use the superseding scan ID to locate the newer PROM in the table. If the scan ID for the superseding PROM is not known, the PROM broadcast code is listed here. If the PROM is superseded by a newer PROM, that part number is listed here. Column 5, TSB REFERENCE NUMBER The TSB NUMBER column identifies the original TSB that released this PROM for service. Whenever possible you should refer to the TSB for additional information before changing a PROM. The bulletin may list other parts that must be installed when the PROM is changed, or it may provide additional troubleshooting information. To find a TSB, see Reading Technical Service Bulletins. See: Reading Technical Service Bulletins This will display all the TSB's for that particular vehicle. EXPANDED FOOTNOTES Here you will find SUPERSEDING SCAN ID, PROM PART NUMBERS, symptoms and additional parts that need to be replaced when servicing the PROM. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Introducing the GM PROM Cross Reference Index > Page 2842 PROM - Programmable Read Only Memory: Application and ID Additional PROM Information New ECM PROMs for GM vehicles may be released for service at any time. The information in this system is accurate to the best of the publisher's knowledge and the publication date of the disk. Before ordering a PROM, consult with a GM parts and service dealer to verify the latest part number information. Scanner PROM ID information for earlier-model vehicles (1980-83) is less complete than for later models. To accurately identify PROM's in earlier vehicles, it may be necessary to check the external PROM code marked on the PROM. General Motors has often recommended that dealership technicians check the PROM history of a vehicle and install the most recent PROM revision before performing other diagnostic operations. Each succeeding PROM revision for a specific vehicle includes all previous revisions. Therefore, whenever you consider changing a PROM, review the entire PROM history to see if any revision covered the current driveability problem. Installing the most recent PROM revision may be impractical however for an independent service facility, particularly if the latest PROM revision does not address the specific driveability problem of the vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Introducing the GM PROM Cross Reference Index > Page 2843 PROM - Programmable Read Only Memory: Application and ID Additional PROM Information New ECM PROMs for GM vehicles may be released for service at any time. The information in this system is accurate to the best of the publisher's knowledge and the publication date of the disk. Before ordering a PROM, consult with a GM parts and service dealer to verify the latest part number information. Scanner PROM ID information for earlier-model vehicles (1980-83) is less complete than for later models. To accurately identify PROM's in earlier vehicles, it may be necessary to check the external PROM code marked on the PROM. General Motors has often recommended that dealership technicians check the PROM history of a vehicle and install the most recent PROM revision before performing other diagnostic operations. Each succeeding PROM revision for a specific vehicle includes all previous revisions. Therefore, whenever you consider changing a PROM, review the entire PROM history to see if any revision covered the current driveability problem. Installing the most recent PROM revision may be impractical however for an independent service facility, particularly if the latest PROM revision does not address the specific driveability problem of the vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Introducing the GM PROM Cross Reference Index > Page 2844 PROM - Programmable Read Only Memory: Application and ID PROM/MEMCAL Identification Marks File In Section: 6E - Engine Fuel & Emission Bulletin No.: 44-65-01 Date: October, 1994 Subject: New PROM/MEMCAL Identification Markings Models: 1995 and Prior Passenger Cars and Trucks Note: For the purposes of this document, the terms PROM and MEMCAL will be used interchangeably. To simplify identification of service PROMs. a new external marking format will be implemented. Parts manufactured after Sept. 1994 will feature these new markings. This change will place the full 8-digit service part number on the PROM, in place of the old 4-digit "EXTERNAL ID" number. In the past, parts and service personnel could not identify a PROM without using a cross-reference table that matched external IDs and service numbers. In the future, the cross-reference table will not be required for PROMs; parts will be ordered directly from the number appearing on the PROM. However, the label will retain the broadcast code alpha characters to allow continued use of cross-reference charts, if so desired. Old Marking Format: New Marking Format: ^ Ordering the above PROM from the old marking format would require using a cross-reference chart to determine a service part number, based on the BROAD CAST CODE and EXTERNAL ID NUMBERS. ^ To order from the new format, simply combine the 2nd and 3rd lines to form an 8-digit part number that can be directly ordered from SPO (number 16134624 in the above example). As these changes are phased into the parts inventory, it should be noted that dealers will continue to see parts with both formats for some time in the future. This is because: ^ Millions of vehicles have already been built with the old format. ^ SPO has existing stock of MEMCALs and PROMs with the old format. ^ PROMS with 7-digit part numbers (representing less than 10% of current part numbers) will continue to use the old format. The 7-digit part numbers are easily identified because they always begin with "122xxxx". Due to manufacturing processes, more than one 8-digit part number may appear on a MEMCAL. In this event, service personnel should use the label on the exterior cover of the MEMCAL assembly. To avoid confusion, only the service label will include the BROAD CAST CODE, consisting of letter characters (I.E., ARCL). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Introducing the GM PROM Cross Reference Index > Page 2845 CHANGES TO MEMCAL/PROM LABELING FORMATS ^ MEMCALs may use either INK-JET or ADHESIVE labels, as shown. ^ PROMs will always use ADHESIVE labels with the same format as shown for MEMCALs. These changes will become effective on parts manufactured after 10/94. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Introducing the GM PROM Cross Reference Index > Page 2846 PROM - Programmable Read Only Memory: Application and ID PROM/MEMCAL Identification Marks File In Section: 6E - Engine Fuel & Emission Bulletin No.: 44-65-01 Date: October, 1994 Subject: New PROM/MEMCAL Identification Markings Models: 1995 and Prior Passenger Cars and Trucks Note: For the purposes of this document, the terms PROM and MEMCAL will be used interchangeably. To simplify identification of service PROMs. a new external marking format will be implemented. Parts manufactured after Sept. 1994 will feature these new markings. This change will place the full 8-digit service part number on the PROM, in place of the old 4-digit "EXTERNAL ID" number. In the past, parts and service personnel could not identify a PROM without using a cross-reference table that matched external IDs and service numbers. In the future, the cross-reference table will not be required for PROMs; parts will be ordered directly from the number appearing on the PROM. However, the label will retain the broadcast code alpha characters to allow continued use of cross-reference charts, if so desired. Old Marking Format: New Marking Format: ^ Ordering the above PROM from the old marking format would require using a cross-reference chart to determine a service part number, based on the BROAD CAST CODE and EXTERNAL ID NUMBERS. ^ To order from the new format, simply combine the 2nd and 3rd lines to form an 8-digit part number that can be directly ordered from SPO (number 16134624 in the above example). As these changes are phased into the parts inventory, it should be noted that dealers will continue to see parts with both formats for some time in the future. This is because: ^ Millions of vehicles have already been built with the old format. ^ SPO has existing stock of MEMCALs and PROMs with the old format. ^ PROMS with 7-digit part numbers (representing less than 10% of current part numbers) will continue to use the old format. The 7-digit part numbers are easily identified because they always begin with "122xxxx". Due to manufacturing processes, more than one 8-digit part number may appear on a MEMCAL. In this event, service personnel should use the label on the exterior cover of the MEMCAL assembly. To avoid confusion, only the service label will include the BROAD CAST CODE, consisting of letter characters (I.E., ARCL). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Introducing the GM PROM Cross Reference Index > Page 2847 CHANGES TO MEMCAL/PROM LABELING FORMATS ^ MEMCALs may use either INK-JET or ADHESIVE labels, as shown. ^ PROMs will always use ADHESIVE labels with the same format as shown for MEMCALs. These changes will become effective on parts manufactured after 10/94. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Introducing the GM PROM Cross Reference Index > Page 2848 PROM - Programmable Read Only Memory: Application and ID Reading Technical Service Bulletins Always read any Technical Service Bulletins (TSB's) referenced before replacing a PROM. Service bulletins list parts that must be installed when a PROM is changed, and provide information on trouble codes, troubleshooting and driveability problems for which the PROM was released. To find applicable TSB's: Complete TSB Listing 1. Hold down right mouse button and select "Vehicle" in the "Pull Right Menu". 2. Select the TSB ICON. 3. Select "All Technical Service Bulletins by Number, Date, and Title". 4. Select "Sort by Number", "Sort by Date", or "Sort by Title". 5. Scroll up or down to find the desired TSB. PROM TSB Listing Only 1. Hold down right mouse button and select "Technical Service Bulletins" in the "Pull Right Menu". 2. Select "All Technical Service Bulletins for PROM - Programmable Read Only Memory". 3. Select "Sort by Number", "Sort by Date", or "Sort by Title". 4. Scroll up or down to find the desired TSB. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Introducing the GM PROM Cross Reference Index > Page 2849 PROM - Programmable Read Only Memory: Application and ID Reading Technical Service Bulletins Always read any Technical Service Bulletins (TSB's) referenced before replacing a PROM. Service bulletins list parts that must be installed when a PROM is changed, and provide information on trouble codes, troubleshooting and driveability problems for which the PROM was released. To find applicable TSB's: Complete TSB Listing 1. Hold down right mouse button and select "Vehicle" in the "Pull Right Menu". 2. Select the TSB ICON. 3. Select "All Technical Service Bulletins by Number, Date, and Title". 4. Select "Sort by Number", "Sort by Date", or "Sort by Title". 5. Scroll up or down to find the desired TSB. PROM TSB Listing Only 1. Hold down right mouse button and select "Technical Service Bulletins" in the "Pull Right Menu". 2. Select "All Technical Service Bulletins for PROM - Programmable Read Only Memory". 3. Select "Sort by Number", "Sort by Date", or "Sort by Title". 4. Scroll up or down to find the desired TSB. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 PROM - Programmable Read Only Memory: Application and ID Footnotes 1 Thru 50 [1] Also needs EGR P/N 1706739. [2] Also requires EGR P/N 17111295. [3] Requires Throttle Body service P/N 17067142, EGR valve service P/N 17067111, Injector service kit P/N 17067976. [4] Requires Throttle Body service P/N 17067142, EGR valve service P/N 17067107, Injector service kit P/N 17067976. [5] Requires Throttle Body service P/N 17067144, EGR valve service P/N 17067110, Injector service kit P/N 17067976. [6] PROM I.D. 7080 KJ is also acceptable for PROM I.D. 5853 KJ only. Requires Throttle Body service P/N 17067144, EGR valve service P/N 17067108 (FED), 17067144 (CAL), Injector service kit P/N 17067976. [7] Required Throttle Body service P/N 17067142, EGR valve service P/N 17067107 (FED), 17068210 (CAL), Injector service kit P/N 17067976. [8] Requires Throttle Body service P/N 17068019, EGR valve service P/N 17067109, Injector service kit P/N 17067976. [9] For Federal - Use 01226047 (PROM CODE 7654 BKW). For California - Use 01226049 (PROM CODE 7665 BKY). [10] For Federal - Use 01226054. For California - Use 01226056 [11] For Federal - Use 01226055. For California - Use 01226057. [12] For Federal - Use 01226046 (PROM CODE 7648 BKU). For California - Use 01226049 (PROM CODE 7665 BKY). [13] For federal - Use 01226046 (PROM CODE 7648 BKU). For California - Use 01226048 (PROM CODE 7659 BKX). [14] ECM may have been replaced by service ECM P/N 16019710 (1225500). [15] ECM may also be 16018161. ECM may also have been replaced by service ECM P/N 16018000 (1225330). [16] ECM may also be 16018201. ECM may also have been replaced by service ECM P/N 16018000 (1225330). [17] ECM may also be 16018211. ECM may have been replaced by service ECM P/N 16018000 (1225330). [18] ECM may also be 16023761. ECM may have been replaced by service ECM P/N 16018000 (1225330). [19] ECM may also be 16018101. ECM may have been replaced by service ECM P/N 16018000 (1225330). [20] For 2-board ECM only. [21] May need EGR valve P/N 17079563. Original equipment P/N 16029014. [22] Original equipment PROM P/N 16017094, now 16025254 [23] Original equipment PROM P/N 16017224, now 16025264. [24] Also needs EGR valve P/N 17079013. Original equipment PROM P/N 16030034 (PROM ID: BOH). [25] Requires kit P/N 25522748 containing: Wiring harness jumper P/N 12043500, Relay P/N 25522747, Foam P/N 25522723, EGR P/N 17079799. [26] Needs EGR valve P/N 17079818. [27] For (MY7) - Use 01226473 (SCAN I.D. = 3941). For (M19) - Use 01226474 (SCAN I.D. = 3951). [28] For (MY7) or (M19, C60) - Use 01226473 (SCAN I.D. = 3941). For (M19) - Use 01226474 (SCAN I.D. = 3951). [29] ECM may also be 16023561(M5), or 16033061(M4 with A/C). [30] For F62 axle - Use 01226441 (SCAN I.D. = 3622). For F17 axle - Use 01226439 (SCAN I.D. = 3332). [31] For one_board ECM only. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2852 [32] Requires Thermac Sensor P/N 8997916. [33] For Federal - Use 01227729 (SCAN I.D. = 7729). For California - Use 01227728 (SCAN I.D. = 7728). [34] Use 01227629 (SCAN I.D. = 7629) only to resolve surge or chuggle. [35] Use 01227381 (SCAN I.D. = 7381) only to resolve chuggle. [36] Use 01227386 (SCAN I.D. = 7386) only to resolve chuggle. [37] Retrofit PROM - Does not supersede the regular replacement service PROM. To be used only as required to resolve cases of chuggle. [38] Retrofit PROM - Supersedes all previous service PROM part numbers. To be used as both the regular service replacement (PROM-damaged or defective), and to resolve cases of chuggle. [39] Retrofit PROM - Supersedes all previous service PROM part numbers. To be used as both the regular service replacement (PROM-damaged or defective), and to resolve cases of chuggle, detonation, or flatness. [40] Retrofit PROM - Does not supersede the regular replacement service PROMS. To be used only as required to resolve cases of chuggle, detonation, or flatness. [41] Need EGR valve P/N 17111577 (Federal only). [42] For use with P215/65 tires - use 01228290 (SCAN I.D. = 8290). For use with P235/60, P245/50 tires - use 01228291 (SCAN I.D. = 8291). [43] For use with P215/65 tires - use 01228292 (SCAN I.D. - 8292). For use with P235/60, P245/50 tires - use 01228293 (SCAN I.D. = 8293). [44] Use 16143570 (SCAN I.D. = 3531) for hot hard restart (Requires Fuel Pump P/N 25115764, Fuel Sender P/N 25093526). Use 16143459 (SCAN I.D. = 3571) for Code 42, Spark Knock, High Idle. [45] Use 16143455 (SCAN I.D. = 3511) for hot hard restart (Requires Fuel Pump P/N 25115764, Fuel Sender P/N 25093526). Use 16143453 (SCAN I.D. = 3501) for Code 42, Spark Knock, High Idle. [46] Use 16143575 (SCAN I.D. = 3541) for hot hard restart (Requires Fuel Pump P/N 25115764). Use 16143460 (SCAN I.D. = 3581) for Code 42, Spark Knock, High Idle. [47] Use 16143580 (SCAN I.D. = 3551) for hot hard restart (Requires Fuel Pump P/N 25115764). Use 16143462 (SCAN I.D. = 3591) for Code 42, Spark Knock, High Idle. [48] Use 16143457 (SCAN I.D. = 3521) for hot hard restart (Requires Fuel Pump P/N 25115925, Fuel Sender P/N 25092778). Use 16143466 (SCAN I.D. = 3481) for Code 42, Spark Knock, High Idle. [49] Use 16143452 (SCAN I.D. = 3491) for hot hard restart (Requires Fuel Pump P/N 25115925, Fuel Sender P/N 25092778). Use 16143463 (SCAN I.D. = 3451) for Code 42, Spark Knock, High Idle. [50] Needs air injection service kit (P/N 10115773) and new vehicle emission control label. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2853 PROM - Programmable Read Only Memory: Application and ID Footnotes 51 Thru 100 [51] Must be ordered with service kit P/N 10115773. [52] With this PROM installed, use 1987-88 2.8L speed density engine driveability and emissions manual. [53] PROM update eliminates MAF sensor, replacing it with a speed density system. With a 1990 or earlier primary cartridge, I.D. vehicle on scanner as a 1989 model (VIN = K-1-W). [54] For 2WD use 16120099 (SCAN I.D. = 9941). For 4WD use 16120109 (SCAN I.D. = 9901). [55] For 2.73 (GU2) Axle use 16120077 (SCAN I.D. = 9891). For 3.08 (GU4) Axle use 16120082 (SCAN I.D. = 9901). For 3.42 (GU6) and 3.73 (GT4) Axles use 16120086 (SCAN I.D. = 9911). [56] For 2WD use 16120042 (SCAN I.D. = 9991). For 4WD use 16120129 (SCAN I.D. = 0011). [57] Needs accelerator pump check ball spring P/N 17069583. [58] For false Code 44 on long coast down, use retrofit service PROM 01228486 AAND 1050. For regular service replacement, use PROM 16062797 AAND 2798. [59] For false Code 44 on long coast down, use retrofit service PROM 01228487 AANF 1052. For regular service replacement, use PROM 16062801 AANF 2802. [60] USE 16143545 (SCAN I.D. = 3461) For hot hard restart (Requires Fuel Pump P/N 25115764, Fuel Sender P/N 25093744). Use 16143465 (SCAN I.D. = 3471) for Code 42, Spark Knock, High Idle. [61] With this PROM installed, use 1987-88 2.8L speed density engine driveability and emissions manual. [62] For use with model C1 Trucks - Use 16121162 (SCAN I.D. = 3511). For use with model C2, K, K2, AND K1000 Trucks - use 16121166 (SCAN I.D. = 3521). [63] Also requires installation of new EGR valve package P/N 17112238 (Contains EGR valve P/N 17090078 and a gasket). [64] Use 16181863 (SCAN I.D. = 0844) for cold start stall. Use 16181859 (SCAN I.D. = 0834) only if required to solve both cold start stall and chuggle. [65] Use 16181871 (SCAN I.D. = 0864) for cold start stall. Use 16181867 (SCAN I.D. = 0854) only if required to solve both cold start stall and chuggle. [66] Use 16165848 (SCAN I.D. = 5614) for cold start stall. Use 16165843 (SCAN I.D. = 5624) only if required to solve both cold start stall and chuggle. [67] Do not rely on the scanner ID to determine which PROM is in a vehicle. Look at the BCC on the PROM to be sure. Do not confuse with some 1991 models with a 2.84 axle ratio and a Federal emissions pkg which used scanner ID 5644 but had a BCC of AWJD. [68] This PROM may have a negative impact on fuel economy. [69] Cannot be used on vehicles that do not have digital EGR valves. [70] Use 16165839 (SCAN I.D. = 5634) for cold start stall. Use 16165829 (SCAN I.D. = 5644) only if required to solve both cold start stall and chuggle. [71] Use 16181883 (SCAN I.D. = 0894) for cold start stall. Use 16181875 (SCAN I.D. = 0874) only if required to solve both cold start stall and chuggle. [72] Use 16181887 (SCAN I.D. = 0904) for cold start stall. Use 16181879 (SCAN I.D. = 0884) only if required to solve both cold start stall and chuggle. [73] This PROM may have a negative impact on fuel economy. [74] PROM can only be used with ECM P/N 16144288. [75] Make certain the vehicle has been updated with previously attempted service fixes as follows: EGR valve P/N 17090156 (stamped on valve) 17112373 (GMSPO kit), PCV valve P/N 25098542, ESC module P/N 16175099 (BCC=BARC). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2854 [76] For vehicles with sleeve bearing engines. [77] Combination detonation and neutral gear rattle PROM available. [78] Needs ESC P/N 16175099. [79] Model 2DDM Transmissions - Check dealer records to see if the torque converter has already been replaced with P/N 8650935 (Tagged BCC: DGAF). Trans. with torque converters with P/N 8656959 (Tagged BCC: DG5F) need to replace it with P/N 8650935. [80] For dedicated natural gas vehicles. Order with kit P/N 12545589 unless the only problem is idle fluctuation. [81] For chuggle at 40-45 condition, use PROM only. For tip-in hesitation only, use EGR valve only - P/N 17078431. For cold driveability hesitation, use both PROM and EGR. [82] Requires supplementary tune-up label, spark bypass relay kit P/N 14086983, spark plugs P/N 5614009, sun visor starting label P/N 14085150. Also, remove and discard fuse labeled "crank" from fuse BLK #2 position (3 Amp. Fuse). [83] Manual transmission cars should also be updated with the clutch anticipate switch per dealer service bulletin number. 91-472-7C. [84] Cold driveability, use with PROM 0051 AAF (G057). REQUIRES THROTTLE BODY SERVICE P/N 17067142, EGR VALVE SERVICE P/N 17067111, INJECTOR SERVICE KIT P/N 17067976. [85] Cold driveability, use with PROM 0050 AAF (G057). REQUIRES THROTTLE BODY SERVICE P/N 17067142, EGR VALVE SERVICE P/N 17067111, INJECTOR SERVICE KIT P/N 17067976. [86] Exhaust noise (requires catalytic converter), cold driveability, use with PROM 5884 BH (G057). REQUIRES THROTTLE BODY SERVICE P/N 17068019, EGR VALVE SERVICE P/N 17067109, INJECTOR SERVICE KIT P/N 17067976. [87] Exhaust noise (requires catalytic converter), cold driveability, use with PROM 5869 BH (G057). REQUIRES THROTTLE BODY SERVICE P/N 17068019, EGR VALVE SERVICE P/N 17067109, INJECTOR SERVICE KIT P/N 17067976. [88] Exhaust noise (requires catalytic converter), cold driveability, use with PROM 5779 KB (G057). REQUIRES THROTTLE BODY SERVICE P/N 17067144, EGR VALVE SERVICE P/N 17067110, INJECTOR SERVICE KIT P/N 17067976. [89] Exhaust noise (requires catalytic converter), cold driveability, use with PROM 5778 KB (G057). REQUIRES THROTTLE BODY SERVICE P/N 17067144, EGR VALVE SERVICE P/N 17067110, INJECTOR SERVICE KIT P/N 17067976. [90] Cold driveability, use with PROM 5854 KJ (G057). PROM I.D. 7080 KJ IS ALSO ACCEPTABLE FOR PROM I.D. 5853 KJ ONLY. REQUIRES THROTTLE BODY SERVICE P/N 17067144, EGR VALVE SERVICE P/N 17067108 (FED), 17067144 (CAL), INJECTOR SERVICE KIT P/N 17067976. [91] Cold driveability, use with PROM 5853 KJ (G057). PROM I.D. 7080 KJ IS ALSO ACCEPTABLE FOR PROM I.D. 5853 KJ ONLY. REQUIRES THROTTLE BODY SERVICE P/N 17067144, EGR VALVE SERVICE P/N 17067108 (FED), 17067144 (CAL), INJECTOR SERVICE KIT P/N 17067976. [92] Cold driveability, use with PROM 5861 KK (G057). REQUIRED THROTTLE BODY SERVICE P/N 17067142, EGR VALVE SERVICE P/N 17067107 (FED), 17068210 (CAL), INJECTOR SERVICE KIT P/N 17067976. [93] Cold driveability, use with PROM 5860 KK (G057). REQUIRED THROTTLE BODY SERVICE P/N 17067142, EGR VALVE SERVICE P/N 17067107 (FED), 17068210 (CAL), INJECTOR SERVICE KIT P/N 17067976. [94] Exhaust noise (requires catalytic converter), cold driveability, use with PROM 5786 LW (G057). REQUIRES THROTTLE BODY SERVICE P/N 17067142, EGR VALVE SERVICE P/N 17067107, INJECTOR SERVICE KIT P/N 17067976. [95] Exhaust noise (requires catalytic converter), cold driveability, use with PROM 5785 LW (G057). REQUIRES THROTTLE BODY SERVICE P/N 17067142, EGR VALVE SERVICE P/N 17067107, INJECTOR SERVICE KIT P/N 17067976. [96] Cold driveability, use with PROM 7088 LY (G057). REQUIRES THROTTLE BODY SERVICE P/N 17067142, EGR VALVE SERVICE P/N 17067111, INJECTOR SERVICE KIT P/N 17067976. [97] Cold driveability, use with PROM 7087 LY (G057). REQUIRES THROTTLE BODY SERVICE P/N 17067142, EGR VALVE SERVICE P/N 17067111, INJECTOR SERVICE KIT P/N 17067976. [98] Chuggle at 40-45 mph, cold driveability hesitation. FOR CHUGGLE AT 40-45 CONDITION, USE PROM ONLY. FOR TIP-IN HESITATION ONLY, USE EGR VALVE ONLY - P/N 17078431. FOR COLD DRIVEABILITY HESITATION, USE BOTH PROM AND EGR. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2855 [99] Driveability correction for heavy chuggle. REQUIRES KIT P/N 25522748 CONTAINING: WIRING HARNESS JUMPER P/N 12043500, RELAY P/N 25522747, FOAM P/N 25522723, EGR P/N 17079799. [100] Cold startability adjustment. REQUIRES SUPPLEMENTARY TUNE-UP LABEL, SPARK BYPASS RELAY KIT P/N 14086983, SPARK PLUGS P/N 5614009, SUN VISOR STARTING LABEL P/N 14085150. ALSO, REMOVE AND DISCARD FUSE LABELED "CRANK" FROM FUSE BLK #2 POSITION (3 AMP. FUSE). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2856 PROM - Programmable Read Only Memory: Application and ID Footnotes 101 Thru 150 [101] Driveability correction for heavy chuggle. REQUIRES KIT P/N 25522748 CONTAINING: WIRING HARNESS JUMPER P/N 12043500, RELAY P/N 25522747, FOAM P/N 25522723, EGR P/N 17079799. [102] Cold startability adjustment. REQUIRES SUPPLEMENTARY TUNE-UP LABEL, SPARK BYPASS RELAY KIT P/N 14086983, SPARK PLUGS P/N 5614009, SUN VISOR STARTING LABEL P/N 14085150. ALSO, REMOVE AND DISCARD FUSE LABELED "CRANK" FROM FUSE BLK #2 POSITION (3 AMP. FUSE). [103] Cold startability adjustment. REQUIRES SUPPLEMENTARY TUNE-UP LABEL, SPARK BYPASS RELAY KIT P/N 14086983, SPARK PLUGS P/N 5614009, SUN VISOR STARTING LABEL P/N 14085150. ALSO, REMOVE AND DISCARD FUSE LABELED "CRANK" FROM FUSE BLK #2 POSITION (3 AMP. FUSE). [104] Cold startability adjustment. REQUIRES SUPPLEMENTARY TUNE-UP LABEL, SPARK BYPASS RELAY KIT P/N 14086983, SPARK PLUGS P/N 5614009, SUN VISOR STARTING LABEL P/N 14085150. ALSO, REMOVE AND DISCARD FUSE LABELED "CRANK" FROM FUSE BLK #2 POSITION (3 AMP. FUSE). [105] Surge. RETROFIT PROM - DOES NOT SUPERSEDE THE REGULAR REPLACEMENT SERVICE PROM. TO BE USED ONLY AS REQUIRED TO RESOLVE CASES OF CHUGGLE. [106] Surge and CODE 51. RETROFIT PROM - SUPERSEDES ALL PREVIOUS SERVICE PROM PART NUMBERS. TO BE USED AS BOTH THE REGULAR SERVICE REPLACEMENT (PROM-DAMAGED OR DEFECTIVE), AND TO RESOLVE CASES OF CHUGGLE. [107] Surge and CODE 51. RETROFIT PROM - SUPERSEDES ALL PREVIOUS SERVICE PROM PART NUMBERS. TO BE USED AS BOTH THE REGULAR SERVICE REPLACEMENT (PROM-DAMAGED OR DEFECTIVE), AND TO RESOLVE CASES OF CHUGGLE. [108] Surge and CODE 51. RETROFIT PROM - SUPERSEDES ALL PREVIOUS SERVICE PROM PART NUMBERS. TO BE USED AS BOTH THE REGULAR SERVICE REPLACEMENT (PROM-DAMAGED OR DEFECTIVE), AND TO RESOLVE CASES OF CHUGGLE. [109] Surge and CODE 51. RETROFIT PROM - SUPERSEDES ALL PREVIOUS SERVICE PROM PART NUMBERS. TO BE USED AS BOTH THE REGULAR SERVICE REPLACEMENT (PROM-DAMAGED OR DEFECTIVE), AND TO RESOLVE CASES OF CHUGGLE. [110] Surge. RETROFIT PROM - SUPERSEDES ALL PREVIOUS SERVICE PROM PART NUMBERS. TO BE USED AS BOTH THE REGULAR SERVICE REPLACEMENT (PROM-DAMAGED OR DEFECTIVE), AND TO RESOLVE CASES OF CHUGGLE. [111] Surge and CODE 51. RETROFIT PROM - SUPERSEDES ALL PREVIOUS SERVICE PROM PART NUMBERS. TO BE USED AS BOTH THE REGULAR SERVICE REPLACEMENT (PROM-DAMAGED OR DEFECTIVE), AND TO RESOLVE CASES OF CHUGGLE. [112] Surge and CODE 51. RETROFIT PROM - SUPERSEDES ALL PREVIOUS SERVICE PROM PART NUMBERS. TO BE USED AS BOTH THE REGULAR SERVICE REPLACEMENT (PROM-DAMAGED OR DEFECTIVE), AND TO RESOLVE CASES OF CHUGGLE, DETONATION, OR FLATNESS. [113] Surge and CODE 51. RETROFIT PROM - SUPERSEDES ALL PREVIOUS SERVICE PROM PART NUMBERS. TO BE USED AS BOTH THE REGULAR SERVICE REPLACEMENT (PROM-DAMAGED OR DEFECTIVE), AND TO RESOLVE CASES OF CHUGGLE, DETONATION, OR FLATNESS. [114] Surge, flatness or tip-in hesitation. RETROFIT PROM - DOES NOT SUPERSEDE THE REGULAR REPLACEMENT SERVICE PROMS. TO BE USED ONLY AS REQUIRED TO RESOLVE CASES OF CHUGGLE, DETONATION, OR FLATNESS. [115] FOR USE WITH P215/65 TIRES - USE 01228290 (SCAN I.D. = 8290). FOR USE WITH P235/60, P245/50 TIRES - USE 01228291 (SCAN I.D. = 8291). [116] FOR USE WITH P215/65 TIRES - USE 01228290 (SCAN I.D. = 8290). FOR USE WITH P235/60, P245/50 TIRES - USE 01228291 (SCAN I.D. = 8291). [117] Spark knock only. USE 16143570 (SCAN I.D. = 3531) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143459 (SCAN I.D. = 3571) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [118] Spark knock only. USE 16143455 (SCAN I.D. = 3511) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143453 (SCAN I.D. = 3501) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [119] Spark knock. USE 16143575 (SCAN I.D. = 3541) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764). USE 16143460 (SCAN I.D. = 3581) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [120] Detonation. USE 16143580 (SCAN I.D. = 3551) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764). USE 16143462 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2857 (SCAN I.D. = 3591) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [121] Stall, sags, hesitation. USE 16143575 (SCAN I.D. = 3541) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764). USE 16143460 (SCAN I.D. = 3581) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [122] USE 16143575 (SCAN I.D. = 3541) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764). USE 16143460 (SCAN I.D. = 3581) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [123] USE 16143570 (SCAN I.D. = 3531) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143459 (SCAN I.D. = 3571) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [124] USE 16143455 (SCAN I.D. = 3511) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143453 (SCAN I.D. = 3501) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [125] USE 16143457 (SCAN I.D. = 3521) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115925, FUEL SENDER P/N 25092778). USE 16143466 (SCAN I.D. = 3481) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [126] USE 16143452 (SCAN I.D. = 3491) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115925, FUEL SENDER P/N 25092778). USE 16143463 (SCAN I.D. = 3451) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [127] USE 16143457 (SCAN I.D. = 3521) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115925, FUEL SENDER P/N 25092778). USE 16143466 (SCAN I.D. = 3481) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [128] USE 16143452 (SCAN I.D. = 3491) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115925, FUEL SENDER P/N 25092778). USE 16143463 (SCAN I.D. = 3451) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [129] Engine stall and/or hesitation after cold start. NEEDS AIR INJECTION SERVICE KIT (P/N 10115773) AND NEW VEHICLE EMISSION CONTROL LABEL. [130] Engine stall and/or hesitation after cold start. NEEDS AIR INJECTION SERVICE KIT (P/N 10115773) AND NEW VEHICLE EMISSION CONTROL LABEL. [131] Driveability conditions and/or stored engine codes. WITH THIS PROM INSTALLED, USE 1987-88 2.8L SPEED DENSITY ENGINE DRIVEABILITY AND EMISSIONS MANUAL. [132] Cold stall and chuggle. DO NOT RELY ON THE SCANNER ID TO DETERMINE WHICH PROM IS IN A VEHICLE. LOOK AT THE BCC ON THE PROM TO BE SURE. DO NOT CONFUSE WITH SOME 1991 MODELS WITH A 2.84 AXLE RATIO AND A FEDERAL EMISSIONS PKG. WITH USED SCANNER ID 5644 BUT HAD A BCC OF AWJD. [133] Driveability conditions and/or stored engine codes. WITH THIS PROM INSTALLED, USE 1987-88 2.8L SPEED DENSITY ENGINE DRIVEABILITY AND EMISSIONS MANUAL. [134] Tip-in hesitation on acceleration; engine stall or sag on cold start; engine stall on deceleration; check engine light with CODES 23,25,33, or 34; or engine speed flare on clutch operation, with manual transmission equipped vehicle. WITH THIS PROM INSTALLED, USE 1987-88 2.8L SPEED DENSITY ENGINE DRIVEABILITY AND EMISSIONS MANUAL. [135] Tip-in hesitation on acceleration; engine stall or sag on cold start; engine stall on deceleration; check engine light with CODES 23,25,33, or 34; or engine speed flare on declutch operation with manual transmission equipped vehicle. WITH THIS PROM INSTALLED, USE 1987-88 2.8L SPEED DENSITY ENGINE DRIVEABILITY AND EMISSIONS MANUAL. [136] Driveability conditions, and/or CODES 23,25,33,34. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [137] Driveability conditions, and/or CODES 23,25,33,34. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [138] Driveability conditions, and/or CODES 23,25,33,34. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [139] Driveability conditions, and/or CODES 23,25,33,34. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2858 [140] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [141] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [142] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [143] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [144] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [145] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [146] PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [147] PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [148] PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [149] Tip-in hesitation on acceleration; engine stall or sag on cold start; engine stall on deceleration; check engine light with CODES 23,25,33, or 34; or engine speed flare on declutch operation with manual transmission equipped vehicle. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [150] Tip-in hesitation on acceleration; engine stall or sag on cold start; engine stall on deceleration; check engine light with CODES 23,25,33, or 34; or engine speed flare on declutch operation with manual transmission equipped vehicle. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2859 PROM - Programmable Read Only Memory: Application and ID Footnotes 151 Thru 200 [151] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [152] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [153] Driveability improvement and eliminate FALSE "Service Engine Soon" lights. FOR 2WD USE 16120099 (SCAN I.D. = 9941). FOR 4WD USE 16120109 (SCAN I.D. = 9901). [154] Driveability improvement and eliminate FALSE "Service Engine Soon" lights. FOR 2.73 (GU2) AXLE USE 16120077 (SCAN I.D. = 9891). FOR 3.08 (GU4) AXLE USE 16120082 (SCAN I.D. = 9901). FOR 3.42 (GU6) AND 3.73 (GT4) AXLES USE 16120086 (SCAN I.D. = 9911). [155] Driveability improvement and eliminate FALSE "Service Engine Soon" lights. FOR 2WD USE 16120042 (SCAN I.D. = 9991). FOR 4WD USE 16120129 (SCAN I.D. = 0011). [156] Prom calibration. FOR FALSE CODE 44 ON LONG COAST DOWN, USE RETROFIT SERVICE PROM 01228486 AAND 1050. FOR REGULAR SERVICE REPLACEMENT, USE PROM 16062797 AAND 2798. [157] FOR FALSE CODE 44 ON LONG COAST DOWN, USE RETROFIT SERVICE PROM 01228487 AANF 1052. FOR REGULAR SERVICE REPLACEMENT, USE PROM 16062801 AANF 2802. [158] Spark knock only. USE 16143570 (SCAN I.D. = 3531) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143459 (SCAN I.D. = 3571) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [159] Spark knock only. USE 16143455 (SCAN I.D. = 3511) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143453 (SCAN I.D. = 3501) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [160] Detonation. USE 16143580 (SCAN I.D. = 3551) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764). USE 16143462 (SCAN I.D. = 3591) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [161] USE 16143545 (SCAN I.D. = 3461) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093744). USE 16143465 (SCAN I.D. = 3471) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [162] USE 16143570 (SCAN I.D. = 3531) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143459 (SCAN I.D. = 3571) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [163] USE 16143545 (SCAN I.D. = 3461) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093744). USE 16143465 (SCAN I.D. = 3471) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [164] USE 16143570 (SCAN I.D. = 3531) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143459 (SCAN I.D. = 3571) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [165] USE 16143455 (SCAN I.D. = 3511) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143453 (SCAN I.D. = 3501) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [166] Hard start when hot and detonation. USE 16143457 (SCAN I.D. = 3521) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115925, FUEL SENDER P/N 25092778). USE 16143466 (SCAN I.D. = 3481) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [167] Hard start when hot and detonation. USE 16143452 (SCAN I.D. = 3491) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115925, FUEL SENDER P/N 25092778). USE 16143463 (SCAN I.D. = 3451) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [168] Engine stall and/or hesitation after cold start. NEEDS AIR INJECTION SERVICE KIT (P/N 10115773) AND NEW VEHICLE EMISSION CONTROL LABEL. [169] Cold stall and chuggle. DO NOT RELY ON THE SCANNER ID TO DETERMINE WHICH PROM IS IN A VEHICLE. LOOK AT THE BCC ON THE PROM TO BE SURE. DO NOT CONFUSE WITH SOME 1991 MODELS WITH A 2.84 AXLE RATIO AND A FEDERAL EMISSIONS PKG. WHICH USED SCANNER ID 5644 BUT HAD A BCC OF AWJD. [170] Engine stall and/or hesitation after cold start. NEEDS AIR INJECTION SERVICE KIT (P/N 10115773) AND NEW VEHICLE EMISSION CONTROL LABEL. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2860 [171] Engine stall and/or hesitation after cold start. MUST BE ORDERED WITH SERVICE KIT P/N 10115773. [172] Driveability conditions and/or stored engine codes. WITH THIS PROM INSTALLED, USE 1987-88 2.8L SPEED DENSITY ENGINE DRIVEABILITY AND EMISSIONS MANUAL. [173] Driveability conditions and/or stored engine codes. WITH THIS PROM INSTALLED, USE 1987-88 2.8L SPEED DENSITY ENGINE DRIVEABILITY AND EMISSIONS MANUAL. [174] Driveability conditions, and/or CODES 23,25,33,34. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [175] Driveability conditions, and/or CODES 23,25,33,34. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [176] Driveability conditions, and/or CODES 23,25,33,34. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [177] Driveability conditions, and/or CODES 23,25,33,34. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [178] Driveability conditions, and/or CODES 23,25,33,34. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [179] Driveability conditions, and/or CODES 23,25,33,34. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [180] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [181] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [182] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [183] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [184] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [185] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [186] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [187] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [188] Driveability conditions, and/or CODES 23,25,33,34. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2861 DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [189] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [190] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [191] Information on PROM calibrations. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [192] Information on PROM calibrations. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [193] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [194] Driveability conditions and/or stored engine codes. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [195] FOR USE WITH MODEL C1 TRUCKS - USE 16121162 (SCAN I.D. = 3511). FOR USE WITH MODEL C2, K, K2, AND K1000 TRUCKS USE 16121166 (SCAN I.D. = 3521). [196] Engine surge. ALSO REQUIRES INSTALLATION OF NEW EGR VALVE PACKAGE P/N 17112238 (CONTAINS EGR VALVE P/N 17090078 AND A GASKET). [197] Engine stall and/or hesitation after cold start. NEEDS AIR INJECTION SERVICE KIT (P/N 10115773) AND NEW VEHICLE EMISSION CONTROL LABEL. [198] Engine stall and/or hesitation after cold start. NEEDS AIR INJECTION SERVICE KIT (P/N 10115773) AND NEW VEHICLE EMISSION CONTROL LABEL. [199] Cold stall and chuggle. DO NOT RELY ON THE SCANNER ID TO DETERMINE WHICH PROM IS IN A VEHICLE. LOOK AT THE BCC ON THE PROM TO BE SURE. DO NOT CONFUSE WITH SOME 1991 MODELS WITH A 2.84 AXLE RATIO AND A FEDERAL EMISSIONS PKG. WHICH USED SCANNER ID 5644 BUT HAD A BCC OF AWJD. [200] Cold stall and chuggle. DO NOT RELY ON THE SCANNER ID TO DETERMINE WHICH PROM IS IN A VEHICLE. LOOK AT THE BCC ON THE PROM TO BE SURE. DO NOT CONFUSE WITH SOME 1991 MODELS WITH A 2.84 AXLE RATIO AND A FEDERAL EMISSIONS PKG. WHICH USED SCANNER ID 5644 BUT HAD A BCC OF AWJD. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2862 PROM - Programmable Read Only Memory: Application and ID Footnotes 201 Thru 250 [201] Cold engine extended crank. USE 16181863 (SCAN I.D. = 0844) FOR COLD START STALL. USE 16181859 (SCAN I.D. = 0834) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [202] Cold engine extended crank. USE 16181863 (SCAN I.D. = 0844) FOR COLD START STALL. USE 16181859 (SCAN I.D. = 0834) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [203] Cold engine extended crank. USE 16181863 (SCAN I.D. = 0844) FOR COLD START STALL. USE 16181859 (SCAN I.D. = 0834) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [204] Cold engine extended crank. USE 16181871 (SCAN I.D. = 0864) FOR COLD START STALL. USE 16181867 (SCAN I.D. = 0854) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [205] Cold engine extended crank. USE 16181871 (SCAN I.D. = 0864) FOR COLD START STALL. USE 16181867 (SCAN I.D. = 0854) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [206] Cold stall and chuggle. DO NOT RELY ON THE SCANNER ID TO DETERMINE WHICH PROM IS IN A VEHICLE. LOOK AT THE BCC ON THE PROM TO BE SURE. DO NOT CONFUSE WITH SOME 1991 MODELS WITH A 2.84 AXLE RATIO AND A FEDERAL EMISSIONS PKG. WHICH USED SCANNER ID 5644 BUT HAD A BCC OF AWJD. [207] Cold engine extended crank. USE 16165848 (SCAN I.D. = 5614) FOR COLD START STALL. USE 16165843 (SCAN I.D. = 5624) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [208] Cold engine extended crank. USE 16165839 (SCAN I.D. = 5634) FOR COLD START STALL. USE 16165829 (SCAN I.D. = 5644) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [209] Cold engine extended crank. USE 16165839 (SCAN I.D. = 5634) FOR COLD START STALL. USE 16165829 (SCAN I.D. = 5644) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [210] Cold engine extended crank. USE 16165848 (SCAN I.D. = 5614) FOR COLD START STALL. USE 16165843 (SCAN I.D. = 5624) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [211] Engine stall, long cranks/idle/decel/surge. CANNOT BE USED ON VEHICLES THAT DO NOT HAVE DIGITAL EGR VALVES. [212] Cold stall and chuggle. DO NOT RELY ON THE SCANNER ID TO DETERMINE WHICH PROM IS IN A VEHICLE. LOOK AT THE BCC ON THE PROM TO BE SURE. DO NOT CONFUSE WITH SOME 1991 MODELS WITH A 2.84 AXLE RATIO AND A FEDERAL EMISSIONS PKG. WHICH USED SCANNER ID 5644 BUT HAD A BCC OF AWJD. [213] Cold engine extended crank. USE 16165848 (SCAN I.D. = 5614) FOR COLD START STALL. USE 16165843 (SCAN I.D. = 5624) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [214] Cold engine extended crank. USE 16165839 (SCAN I.D. = 5634) FOR COLD START STALL. USE 16165829 (SCAN I.D. = 5644) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [215] Cold engine extended crank. USE 16165839 (SCAN I.D. = 5634) FOR COLD START STALL. USE 16165829 (SCAN I.D. = 5644) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [216] Cold start extended crank. Engine starts with ignition key cycled. USE 16181883 (SCAN I.D. = 0894) FOR COLD START STALL. USE 16181875 (SCAN I.D. = 0874) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [217] Cold start extended crank, engine starts with ignition key cycled. USE 16181883 (SCAN I.D. = 0894) FOR COLD START STALL. USE 16181875 (SCAN I.D. = 0874) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [218] Cold engine extended crank. USE 16181887 (SCAN I.D. = 0904) FOR COLD START STALL. USE 16181879 (SCAN I.D. = 0884) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [219] Cold engine extended crank. USE 16181887 (SCAN I.D. = 0904) FOR COLD START STALL. USE 16181879 (SCAN I.D. = 0884) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [220] Cold engine extended crank. USE 16165848 (SCAN I.D. = 5614) FOR COLD START STALL. USE 16165843 (SCAN I.D. = 5624) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [221] Surge or chuggle on decel and/or rough idle. PROM CAN ONLY BE USED WITH ECM P/N 16144288. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2863 [222] Surge or chuggle on decel and/or rough idle. PROM CAN ONLY BE USED WITH ECM P/N 16144288. [223] Engine stall. MANUAL TRANSMISSION CARS SHOULD ALSO BE UPDATED WITH THE CLUTCH ANTICIPATE SWITCH PER DEALER SERVICE BULLETIN NO. 91-472-7C. [224] USE 16165848 (SCAN I.D. = 5614) FOR COLD START STALL. USE 16165843 (SCAN I.D. = 5624) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [225] USE 16165839 (SCAN I.D. = 5634) FOR COLD START STALL. USE 16165829 (SCAN I.D. = 5644) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [226] USE 16165839 (SCAN I.D. = 5634) FOR COLD START STALL. USE 16165829 (SCAN I.D. = 5644) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [227] Cold engine extended crank. USE 16165848 (SCAN I.D. = 5614) FOR COLD START STALL. USE 16165843 (SCAN I.D. = 5624) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [228] Cold engine extended crank. USE 16165839 (SCAN I.D. = 5634) FOR COLD START STALL. USE 16165829 (SCAN I.D. = 5644) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [229] Cold engine extended crank. USE 16165839 (SCAN I.D. = 5634) FOR COLD START STALL. USE 16165829 (SCAN I.D. = 5644) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [230] Surge or chuggle on decel and/or rough idle. PROM CAN ONLY BE USED WITH ECM P/N 16144288. [231] MAKE CERTAIN THE VEHICLE HAS BEEN UPDATED WITH PREVIOUSLY ATTEMPTED SERVICE FIXES AS FOLLOWS: EGR VALVE P/N 17090156 (STAMPED ON VALVE) 17112373 (GMSPO KIT), PCV VALVE P/N 25098542, ESC MODULE P/N 16175099 (BCC=BARC). [232] Driveability improvements. MAKE CERTAIN THE VEHICLE HAS BEEN UPDATED WITH PREVIOUSLY ATTEMPTED SERVICE FIXES AS FOLLOWS: EGR VALVE P/N 17090156 (STAMPED ON VALVE) 17112373 (GMSPO KIT), PCV VALVE P/N 25098542, ESC MODULE P/N 16175099 (BCC=BARC). [233] Driveability improvements. MAKE CERTAIN THE VEHICLE HAS BEEN UPDATED WITH PREVIOUSLY ATTEMPTED SERVICE FIXES AS FOLLOWS: EGR VALVE P/N 17090156 (STAMPED ON VALVE) 17112373 (GMSPO KIT), PCV VALVE P/N 25098542, ESC MODULE P/N 16175099 (BCC=BARC). [234] Driveablity improvements. MAKE CERTAIN THE VEHICLE HAS BEEN UPDATED WITH PREVIOUSLY ATTEMPTED SERVICE FIXES AS FOLLOWS: EGR VALVE P/N 17090156 (STAMPED ON VALVE) 17112373 (GMSPO KIT), PCV VALVE P/N 25098542, ESC MODULE P/N 16175099 (BCC=BARC). [235] Driveability improvements. MAKE CERTAIN THE VEHICLE HAS BEEN UPDATED WITH PREVIOUSLY ATTEMPTED SERVICE FIXES AS FOLLOWS: EGR VALVE P/N 17090156 (STAMPED ON VALVE) 17112373 (GMSPO KIT), PCV VALVE P/N 25098542, ESC MODULE P/N 16175099 (BCC=BARC). [236] Center Port Fuel Injection noise. FOR VEHICLES WITH SLEEVE BEARING ENGINES. [237] Neutral gear rattle only. COMBINATION DETONATION AND NEUTRAL GEAR RATTLE PROM AVAILABLE. [238] Driveability improvements. MAKE CERTAIN THE VEHICLE HAS BEEN UPDATED WITH PREVIOUSLY ATTEMPTED SERVICE FIXES AS FOLLOWS: EGR VALVE P/N 17090156 (STAMPED ON VALVE) 17112373 (GMSPO KIT), PCV VALVE P/N 25098542, ESC MODULE P/N 16175099 (BCC=BARC). [239] TCC chuggle. MODEL 2DDM TRANSMISSIONS - CHECK DEALER RECORDS TO SEE IF THE TORQUE CONVERTER HAS ALREADY BEEN REPLACED WITH P/N 8650935 (TAGGED BCC: DGAF). TRANS. WITH TORQUE CONVERTERS WITH P/N 8656959 (TAGGED BCC: DG5F) NEED TO REPLACE IT WITH P/N 8650935. [240] Unstable idle in park or neutral/poor driveability. FOR DEDICATED NATURAL GAS VEHICLES. ORDER WITH KIT P/N 12545589 UNLESS THE ONLY PROBLEM IS IDLE FLUCTUATION. [241] Driveability improvements. MAKE CERTAIN THE VEHICLE HAS BEEN UPDATED WITH PREVIOUSLY ATTEMPTED SERVICE FIXES AS FOLLOWS: EGR VALVE P/N 17090156 (STAMPED ON VALVE) 17112373 (GMSPO KIT), PCV VALVE P/N 25098542, ESC MODULE P/N 16175099 (BCC=BARC). [242] Information on PROM calibrations. CANNOT BE USED ON VEHICLES THAT DO NOT HAVE DIGITAL EGR VALVES. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2864 [243] TCC chuggle. MODEL 2DDM TRANSMISSIONS - CHECK DEALER RECORDS TO SEE IF THE TORQUE CONVERTER HAS ALREADY BEEN REPLACED WITH P/N 8650935 (TAGGED BCC: DGAF). TRANS. WITH TORQUE CONVERTERS WITH P/N 8656959 (TAGGED BCC: DG5F) NEED TO REPLACE IT WITH P/N 8650935. [244] TCC chuggle. MODEL 2DDM TRANSMISSIONS - CHECK DEALER RECORDS TO SEE IF THE TORQUE CONVERTER HAS ALREADY BEEN REPLACED WITH P/N 8650935 (TAGGED BCC: DGAF). TRANS. WITH TORQUE CONVERTERS WITH P/N 8656959 (TAGGED BCC: DG5F) NEED TO REPLACE IT WITH P/N 8650935. [245] Tip-in hesitation on acceleration; engine stall or sag on cold start; engine stall on deceleration; check engine light with CODES 23,25,33, or 34; or engine speed flare on declutch operation with manual transmission equipped vehicle. [246] Tip-in hesitation on acceleration; engine stall or sag on cold start; engine stall on deceleration; check engine light with CODES 23,25,33, or 34; or engine speed flare on declutch operation with manual transmission equipped vehicle. [247] Check engine light comes on while idling on vehicles equipped with Computer Controlled Emission System (C.C.E.S.), driven in altitudes above 3000 feet. [248] Engine may stop running during parking maneuver or during coast down at low speeds during ambient temperature above 85°F. [249] Tip-in hesitation on acceleration; engine stall or sag on cold start; engine stall on deceleration; check engine light with CODES 23,25,33, or 34; or engine speed flare on declutch operation with manual transmission equipped vehicle. [250] Surge on acceleration and/or at road load speeds, false "Service Engine Soon" light (CODE 32), poor driveability during warm up, Detonation under load. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2865 PROM - Programmable Read Only Memory: Application and ID Footnotes 251 Thru 300 [251] Hesitation or sag during the first two minutes of cold operation while vehicle is under moderate to heavy throttle drive away, or TCC chuggle. [252] Cold start-stall, hesitation, or sag when the engine coolant is between 36°F to 111°F (2°C to 44°C); or Inadequate AC performance when driving at a steady speed and throttle position, between 24 to 64 MPH, when the cruise control is not being used. [253] Lack of throttle response on trucks equipped with governors; or hot restart driveaway sag, both governor and non-governor trucks. [254] Intermittent stall after cold start; engine stalling on coast down; hesitation cold; or ECM CODES E22,E26,E32,E55,E70, and/or E85 [255] PROM I.D. 7080 KJ is also acceptable for PROM I.D. 5853 KJ only. Requires Throttle body service P/N 17067144, EGR valve] service P/N 17067108 (FED), 17067144 (CAL), Injector service kit P/N 17067976. [256] Requires Throttle body service P/N 17067142, EGR valve service P/N 17067107 (FED), 17068210 (CAL), Injector service kit P/N 17067976. [257] FOR CHUGGLE AT 40-45 CONDITION, USE PROM ONLY. FOR TIP-IN HESITATION ONLY, USE EGR VALVE ONLY - P/N 17078431. FOR COLD DRIVEABILITY HESITATION, USE BOTH PROM AND EGR. [258] REQUIRES SUPPLEMENTARY TUNE-UP LABEL, SPARK BYPASS RELAY KIT P/N 015 14086983, SPARK PLUGS P/N 5614009, SUN VISOR STARTING LABEL P/N 015 14085150. ALSO, REMOVE AND DISCARD FUSE LABELED "CRANK" FROM FUSE BLK #2 POSITION (3 AMP. FUSE). [259] DO NOT RELY ON THE SCANNER ID TO DETERMINE WHICH PROM IS IN A VEHICLE. LOOK AT THE BCC ON THE PROM TO BE SURE. DO NOT CONFUSE WITH SOME 1991 MODELS WITH A 2.84 AXLE RATIO AND A FEDERAL EMISSIONS PACKAGE WITH USED SCANNER ID 5644 BUT HAD A [260] DO NOT RELY ON THE SCANNER ID TO DETERMINE WHICH PROM IS IN A VEHICLE. LOOK AT THE BCC ON THE PROM TO BE SURE. DO NOT CONFUSE WITH SOME 1991 MODELS WITH A 2.84 AXLE RATIO AND A FEDERAL EMISSIONS PACKAGE WITH USED SCANNER ID 5644 BUT HAD A [261] DO NOT RELY ON THE SCANNER ID TO DETERMINE WHICH PROM IS IN A VEHICLE. LOOK AT THE BCC ON THE PROM TO BE SURE. DO NOT CONFUSE WITH SOME 1991 MODELS WITH A 2.84 AXLE RATIO AND A FEDERAL EMISSIONS PACKAGE WITH USED SCANNER ID 5644 BUT HAD A [262] MAKE CERTAIN THE VEHICLE HAS BEEN UPDATED WITH PREVIOUSLY AT TEMPTED SERVICE FIXES AS FOLLOWS: EGR VALVE P/N 17090156 (STAMPED ON VALVE) 17112373 (GMSPO KIT), PCV VALVE P/N 25098542, ESC MODULE P/N 16175099 (BCC=BARC). [263] MAKE CERTAIN THE VEHICLE HAS BEEN UPDATED WITH PREVIOUSLY ATTEMPTED SERVICE FIXES AS FOLLOWS: EGR VALVE P/N 17090156 (STAMPED ON VALVE) 17112373 (GMSPO KIT), PCV VALVE P/N 25098542, ESC MODULE P/N 16175099 (BCC=BARC). [264] MODEL 2DDM TRANS. CARS - CHECK DLR. RECORDS TO SEE IF THE TORQUE CONVERTER HAS ALREADY BEEN REPLACED WITH PN 8650935 (BCC: DGAF). TRANSMISSIONS WITH TORQUE CONVERTERS WITH PN 8656959 (BCC: DG5F) NEED TO HAVE THE TORQUE CONVERTER REPLACED W [265] MODEL 2DDM TRANS. CARS - CHECK DLR. RECORDS TO SEE IF THE TORQUE CONVERTER HAS ALREADY BEEN REPLACED WITH PN 8650935 (BCC: DGAF). TRANSMISSIONS WITH TORQUE CONVERTERS WITH PN 8656959 (BCC: DG5F) NEED TO HAVE THE TORQUE CONVERTER REPLACED W [266] Vehicles equipped with Computer Controlled Emission System (C.C.E.S) experience a Check Engine Light coming on while idling, usually when idling time exceeds 2 minutes with transmission in gear in altitudes above 3000 feet. [267] Cold driveability, use with PROM 5854 KJ (G057). PROM I.D. 7080 KJ IS ALSO ACCEPTABLE FOR PROM I.D. 5853 KJ ONLY. REQUIRES THROTTLE BODY SERVICE P/N 17067144, EGR VALVE SERVICE P/N 17067108 (FED), 17067144 (CAL), INJECTOR SERVICE KIT P/N 17067976. [268] Cold driveability, use with PROM 5853 KJ (G057). PROM I.D. 7079 KJ IS ALSO ACCEPTABLE FOR PROM I.D. 5854 KJ ONLY. REQUIRES THROTTLE BODY SERVICE P/N 17067144, EGR VALVE SERVICE P/N 17067108 (FED), 17067144 (CAL), INJECTOR SERVICE KIT P/N 17067976. [269] Cold driveability, use with PROM 5861 KK (G057). REQUIRES THROTTLE BODY SERVICE P/N 17067142, EGR VALVE SERVICE P/N 17067107 (FED), 17068210 (CAL), INJECTOR SERVICE KIT P/N 17067976. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2866 [270] Cold driveability, use with PROM 5860 KK (G057). REQUIRES THROTTLE BODY SERVICE P/N 17067142, EGR VALVE SERVICE P/N 17067107 (FED), 17068210 (CAL), INJECTOR SERVICE KIT P/N 17067976. [271] Tip-in hesitation, lack low speed performance. Used with Manual transaxle vehicles with A/C only. Requires EGR TVS P/N 373510, and A.I.R. valve P/N 17082701. [272] Weak drive-away after cold start, requires EGR TVS P/N 373510. Also, for CALIFORNIA emissions, manual transaxle, replace A.I.R. management valve with PN 17082701. [273] Level road surge, tip-in hesitation, lack of low speed performance - for automatic transaxles only. (Requires EGR valve P/N 17068212). FOR FEDERAL - USE 01226055. FOR CALIFORNIA - USE 01226057. [274] Stall in coast down with clutch disengaged and A/C on, weak drive away after cold start , requires EGR TVS P/N 373510. Also, for CALIFORNIA emissions, manual transaxle, replace A.I.R. management valve with PN 17082701. [275] Idle shake, detonation (G043). FOR 2.5L EFI, AUTOMATIC TRANSAXLE, AND FIRST DESIGN (3-BOARD) ECM. THE SECOND DESIGN (2-BOARD) ECM HAS THE SPARK REVISION ALREADY INCORPORATED IN ITS PROM. [276] Chuggle/surge at 40-45 MPH, tip-in hesitation/sag, spark knock, requires EGR valve (G032). FOR CHUGGLE AT 40-45 CONDITION, USE PROM ONLY. FOR TIP-IN HESITATION ONLY, USE EGR VALVE ONLY - P/N 17078431. FOR COLD DRIVEABILITY HESITATION, USE BOTH PROM AND EGR. [277] Chuggle and surge at 35-55 MPH, requires EGR kit. REQUIRES KIT P/N 25522748 CONTAINING: WIRING HARNESS JUMPER P/N 12043500, RELAY P/N 25522747, FOAM P/N 25522723, EGR P/N 17079799. [278] CODE 42, spark knock, cold startability, plug fouling (G040). REQUIRES SUPPLEMENTARY TUNE-UP LABEL, SPARK BYPASS RELAY KIT P/N 14086983, SPARK PLUGS P/N 5614009, SUN VISOR STARTING LABEL P/N 14085150. ALSO, REMOVE AND DISCARD FUSE LABELED "CRANK" FROM FUSE BLK #2 POSITION (3 AMP. FUSE). [279] Chuggle and surge at 35-55 MPH, requires EGR kit (G040). REQUIRES KIT P/N 25522748 CONTAINING: WIRING HARNESS JUMPER P/N 12043500, RELAY P/N 25522747, FOAM P/N 25522723, EGR P/N 17079799. [280] Cold hesitation/sag, warm surge (G082). RETROFIT PROM SUPERSEDES ALL PREVIOUS SERVICE PROM PART NUMBERS. TO BE USED AS BOTH THE REGULAR SERVICE REPLACEMENT (PROM-DAMAGED OF DEFECTIVE), AND TO RESOLVE CASES OF CHUGGLE, DETONATION, OR FLATNESS. [281] TCC chuggle or surge (G043). WHEN INSTALLING PROM IN A CANADIAN 1985 NB, A CODE 13 WILL OCCUR AS THE VEHICLE WAS NOT EQUIPPED WITH AN O2 SENSOR. TO ELIMINATE THE CODE 13, NEED TO INSTALL O2 SENSOR # 8990741 AND CONNECT TO THE EXISTING PURPLE WIRE AND CONNECTOR IN THE [282] Surge or chuggle at 52-60 MPH (G071). RETROFIT PROM - DOES NOT SUPERSEDE THE REGULAR REPLACEMENT SERVICE PROM. TO BE USED ONLY AS REQUIRED TO RESOLVE CASES OF CHUGGLE. [283] Surge or chuggle at 52-60 MPH (G071). RETROFIT PROM - SUPERSEDES ALL PREVIOUS SERVICE PROM PART NUMBERS. TO BE USED AS BOTH THE REGULAR SERVICE REPLACEMENT (PROM-DAMAGED OR DEFECTIVE), AND TO RESOLVE CASES OF CHUGGLE. [284] Chuggle, hesitation, tip-in spark knock. RETROFIT PROM - SUPERSEDES ALL PREVIOUS SERVICE PROM PART NUMBERS. TO BE USED AS BOTH THE REGULAR SERVICE REPLACEMENT (PROM-DAMAGED OR DEFECTIVE), AND TO RESOLVE CASES OF CHUGGLE, DETONATION, OR FLATNESS. [285] Chuggle, hesitation, tip-in spark knock. RETROFIT PROM - DOES NOT SUPERSEDE THE REGULAR REPLACEMENT SERVICE PROMS. TO BE USED ONLY AS REQUIRED TO RESOLVE CASES OF CHUGGLE, DETONATION, OR FLATNESS. [286] FOR USE WITH P215/65 TIRES - USE 01228290 (SCAN I.D. = 8290). FOR USE WITH P235/60, P245/50 TIRES - USE 01228291 (SCAN I.D. = 8291). [287] FOR USE WITH P215/65 TIRES - USE 01228292 (SCAN I.D. = 8292). FOR USE WITH P235/60, P245/50 TIRES - USE 01228293 (SCAN I.D. = 8293). [288] FALSE CODES 33, 34, 43, rough idle, chuggle, hesitation (G006,G007). USED WITH VIN #119016 OR LATER ALUMINUM HEAD CORVETTES AND ALL CONVERTIBLE MODELS WITH AUTOMATIC TRANSMISSION, 2.59 (GM1) AXLE ONLY. [289] FALSE CODES 33, 34, 43, rough idle, chuggle, hesitation (G006,G007). USED FOR VIN #119016 OR LATER ALUMINUM HAED CORVETTES AND ALL CONVERTIBLE MODELS WITH AUTOMATIC TRANSMISSION, 2.73 (GU2)/3.07 (G44) AXLE ONLY. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2867 [290] Spark knock. USE 16143570 (SCAN I.D. = 3531) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143459 (SCAN I.D. = 3571) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [291] Spark knock. USE 16143455 (SCAN I.D. = 3511) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143453 (SCAN I.D. = 3501) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [292] Spark knock (G055). USE 16143575 (SCAN I.D. = 3541) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764). USE 16143460 (SCAN I.D. = 3581) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [293] Spark knock (G043). USE 16143580 (SCAN I.D. = 3551) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764). USE 16143462 (SCAN I.D. = 3591) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [294] Stalling, tip-in hesitation/sag, rough idle, cold driveability. USE 16143575 (SCAN I.D. = 3541) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764). USE 16143460 (SCAN I.D. = 3581) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [295] Hard hot restart (requires rubber bumper pkg PN 25004553, and a pulsator package PN 25094266), or CODE 42, intermittent high idle, spark knock (G055). [296] USE 16143575 (SCAN I.D. = 3541) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764). USE 16143460 (SCAN I.D. = 3581) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [297] USE 16143570 (SCAN I.D. = 3531) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143459 (SCAN I.D. = 3571) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [298] USE 16143455 (SCAN I.D. = 3511) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143453 (SCAN I.D. = 3501) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [299] USE 16143455 (SCAN I.D. = 3511) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143453 (SCAN I.D. = 3501) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [300] Spark knock. USE 16143457 (SCAN I.D. = 3521) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115925, FUEL SENDER P/N 25092778). USE 16143466 (SCAN I.D. = 3481) FOR CODE 42, SPARK KNOCK, HIGH IDLE. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2868 PROM - Programmable Read Only Memory: Application and ID Footnotes 301 Thru 350 [301] Spark knock. USE 16143452 (SCAN I.D. = 3491) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115925, FUEL SENDER P/N 25092778). USE 16143463 (SCAN I.D. = 3451) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [302] Hard start hot (requires installation of a rubber bumper pkg PN 25004553, and a pulsator pkg PN 25094266) or CODE 42, high idle, spark knock (G055). [303] USE 16143457 (SCAN I.D. = 3521) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115925, FUEL SENDER P/N 25092778). USE 16143466 (SCAN I.D. = 3481) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [304] Hard hot restart (requires rubber bumper pkg PN 25004553, and a pulsator package PN 25094266), or CODE 42, intermittent high idle, spark knock (G055). [305] USE 16143452 (SCAN I.D. = 3491) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115925, FUEL SENDER P/N 25092778). USE 16143463 (SCAN I.D. = 3451) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [306] Tip-in hesitation,stall,CODES 23,25,33,or 34, or speed flare on declutch op. w/man. trans. (CODE 23 or 25 require MAT sensor model year diagnostics) (G027). WITH THIS PROM INSTALLED, USE 1987-88 2.8L SPEED DENSITY ENGINE DRIVEABILITY AND EMISSIONS MANUAL. [307] CODES 23, 25, 33, 34, driveability and stalling (G027). PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [308] Tip-in hesitation,stall,CODES 23,25,33,or 34, or speed flare on declutch op. w/man. trans. (CODE 23 or 25 require MAT sensor model year diagnostics). PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [309] Code 23, 25, 33, 34, driveability and stalling. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [310] Tip-in hesitation,stall,CODES 23,25,33,or 34, or speed flare on declutch op. w/man. trans. (CODE 23 or 25 require MAT sensor model year diagnostics) (G027). PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [311] High emissions, exhaust odor, starting and driveability problems (G046). Requires Connector Bleed Assembly P/N 10105820 [312] FALSE CODES 43, 54, unstable idle. FOR 2.73 (GU2) AXLE USE 16120077 (SCAN I.D. = 9891). FOR 3.08 (GU4) AXLE USE 16120082 (SCAN I.D. = 9901). FOR 3.42 (GU6) AND 3.73 (GT4) AXLES USE 16120086 (SCAN I.D. = 9911). [313] Running change. FOR FALSE CODE 44 ON LONG COAST DOWN, USE RETROFIT SERVICE PROM 01228486 SCAN I.D. 8486, AAND 1050. FOR REGULAR SERVICE REPLACEMENT, USE PROM 16062797 SCAN I.D. 2223, AAND 2798. [314] Running change. FOR FALSE CODE 44 ON LONG COAST DOWN, USE RETROFIT SERVICE PROM 01228487 SCAN I.D. 8487, AANF 1052. FOR REGULAR SERVICE REPLACEMENT, USE PROM 16062801 SCAN I.D. 2233, AANF 2802. [315] Surge on acceleration and/or at road load speeds, false "Service Engine Soon" light (CODE 32), poor driveability during warm up, Detonation under load (G052). [316] Spark knock. USE 16143570 (SCAN I.D. = 3531) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143459 (SCAN I.D. = 3571) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [317] Spark knock. USE 16143455 (SCAN I.D. = 3511) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143453 (SCAN I.D. = 3501) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [318] Spark knock (G043). USE 16143580 (SCAN I.D. = 3551) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764). USE 16143462 (SCAN I.D. = 3591) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [319] Spark knock (G055). USE 16143545 (SCAN I.D. = 3461) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093744). USE 16143465 (SCAN I.D. = 3471) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [320] CODE 42, spark knock, intermittent high idle. IF MAJOR CONDITION IS HARD HOT ENGINE RESTART, PROM ALSO REQUIRES INSTALLATION OF A RUBBER BUMPER PKG PN 25004553, AND PULSATOR PKG PN 25094266. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2869 [321] USE 16143545 (SCAN I.D. = 3461) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093744). USE 16143465 (SCAN I.D. = 3471) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [322] USE 16143570 (SCAN I.D. = 3531) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143459 (SCAN I.D. = 3571) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [323] USE 16143455 (SCAN I.D. = 3511) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115764, FUEL SENDER P/N 25093526). USE 16143453 (SCAN I.D. = 3501) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [324] Spark knock. USE 16143457 (SCAN I.D. = 3521) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115925, FUEL SENDER P/N 25092778). USE 16143466 (SCAN I.D. = 3481) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [325] Spark knock. USE 16143452 (SCAN I.D. = 3491) FOR HOT HARD RESTART (REQUIRES FUEL PUMP P/N 25115925, FUEL SENDER P/N 25092778). USE 16143463 (SCAN I.D. = 3451) FOR CODE 42, SPARK KNOCK, HIGH IDLE. [326] Tip-in hesitation, stall, CODES 23, 25, 33, or 34, or speed flare on declutch op. w/man. trans. (CODE 23 or 25 require MAT sensor model year diagnostics) (G027). WITH THIS PROM INSTALLED, USE 1987-88 2.8L SPEED DENSITY ENGINE DRIVEABILITY AND EMISSIONS MANUAL. [327] CODES 23, 25, 33, 34. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [328] Tip-in hesitation,stall,CODES 23,25,33,or 34, or speed flare on declutch op. w/ man. trans. (CODE 23 or 25 require MAT sensor model year diagnostics). PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [329] Tip-in hesitation,stall,CODES 23,25,33,or 34, or speed flare on declutch op. w/ man. trans. (CODE 23 or 25 require MAT sensor model year diagnostics) (G027). PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [330] CODES 23, 25, 33, 34, driveability and stalling (G027). PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [331] Code 23, 25, 33, 34, driveability and stalling. PROM UPDATE ELIMINATES MAF SENSOR, REPLACING IT WITH A SPEED DENSITY SYSTEM. WITH A 1990 OR EARLIER PRIMARY CARTRIDGE, I.D. VEHICLE ON SCANNER AS A 1989 MODEL (VIN = K-1-W). [332] FOR USE WITH MODEL C1 TRUCKS - USE 16121162 (SCAN I.D. = 3511). FOR USE WITH MODEL C2, K, K2, AND K1000 TRUCKS USE 16121166 (SCAN I.D. = 3521). [333] Surge on acceleration and/or at road load speeds, false "Service Engine Soon" light (CODE 32), poor driveability during warm up, Detonation under load (G052). [334] Cold engine extended crank. USE 16181863 (SCAN I.D. = 0844) FOR COLD START STALL. USE 16181859 (SCAN I.D. = 0834) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [335] [Cold engine extended crank. USE 16181871 (SCAN I.D. = 0864) FOR COLD START STALL. USE 16181867 (SCAN I.D. = 0854) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [336] Engine does not stay running on initial cold start and chuggle at 35-45 MPH with TCC engaged. New MEM-CAL may affect fuel economy. DO NOT RELY ON THE SCANNER ID TO DETERMINE WHICH PROM IS IN A VEHICLE. LOOK AT THE BCC ON THE PROM TO BE SURE. DO NOT CONFUSE WITH SOME 1991 MODELS WITH A 2.84 AXLE RATIO AND A FEDERAL EMISSIONS PACKAGE WITH SCANNER ID 5644 BUT A BCC OF A] [337] Cold engine extended crank. USE 16165848 (SCAN I.D. = 5614) FOR COLD START STALL. USE 16165843 (SCAN I.D. = 5624) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [338] Cold engine extended crank. USE 16165839 (SCAN I.D. = 5634) FOR COLD START STALL. USE 16165829 (SCAN I.D. = 5644) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [339] Cold engine extended crank. USE 16165839 (SCAN I.D. = 5634) FOR COLD START STALL. USE 16165829 (SCAN I.D. = 5644) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [340] Cold engine extended crank. USE 16165848 (SCAN I.D. = 5614) FOR COLD START STALL. USE 16165843 (SCAN I.D. = 5624) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2870 [341] Hesitation or sag during the first two minutes of cold operation while vehicle is under moderate to heavy throttle driveaway, or TCC chuggle. [342] Cold start-stall, hesitation, or sag when the engine coolant is between 36°F - 111°F (2°C 44°C); or Inadequate A/C performance when driving at steady speed and throttle position, between 24 - 64 MPH, when the cruise control is not being used. [343] Engine does not stay running on initial cold start and chuggle at 35-45 MPH with TCC engaged. New MEM-CAL may affect fuel economy. DO NOT RELY ON THE SCANNER ID TO DETERMINE WHICH PROM IS IN A VEHICLE. LOOK AT THE BCC ON THE PROM TO BE SURE. DO NOT CONFUSE WITH SOME 1991 MODELS WITH A 2.84 AXLE RATIO AND A FEDERAL EMISSIONS PACKAGE WITH SCANNER ID 5644 BUT A BCC OF A [344] Cold engine extended crank. USE 16165848 (SCAN I.D. = 5614) FOR COLD START STALL. USE 16165843 (SCAN I.D. = 5624) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [345] Cold engine extended crank. USE 16165839 (SCAN I.D. = 5634) FOR COLD START STALL. USE 16165829 (SCAN I.D. = 5644) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [346] Cold engine extended crank. USE 16181883 (SCAN I.D. = 0894) FOR COLD START STALL. USE 16181875 (SCAN I.D. = 0874) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [347] Cold engine extended crank. USE 16181887 (SCAN I.D. = 0904) FOR COLD START STALL. USE 16181879 (SCAN I.D. = 0884) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [348] Service Engine Soon light (SES) with a code 43 or tip-in sag, tip-in hesitation, surge at WOT, or spark detonation when cold. [349] Engine stall. MANUAL TRANSMISSION CARS SHOULD ALSO BE UPDATED WITH THE CLUTCH ANTICIPATE SWITCH PER DEALER SERVICE BULLETIN NO. 91-472-7C. [350] Engine does not stay running on initial cold start and chuggle at 35-45 MPH with TCC engaged. New MEM-CAL may affect fuel economy. DO NOT RELY ON THE SCANNER ID TO DETERMINE WHICH PROM IS IN A VEHICLE. LOOK AT THE BCC ON THE PROM TO BE SURE. DO NOT CONFUSE WITH SOME 1991 MODELS WITH A 2.84 AXLE RATIO AND A FEDERAL EMISSIONS PACKAGE WITH SCANNER ID 5644 BUT A BCC OF A. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Footnotes 1 Thru 50 > Page 2871 PROM - Programmable Read Only Memory: Application and ID Footnotes 351 Thru 400 [351] USE 16165848 (SCAN I.D. = 5614) FOR COLD START STALL. USE 16165843 (SCAN I.D. = 5624) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [352] USE 16165839 (SCAN I.D. = 5634) FOR COLD START STALL. USE 16165829 (SCAN I.D. = 5644) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [353] Cold engine extended crank. USE 16165839 (SCAN I.D. = 5634) FOR COLD START STALL. USE 16165829 (SCAN I.D. = 5644) ONLY IF REQUIRED TO SOLVE BOTH COLD START STALL AND CHUGGLE. [354] Lack of throttle response on trucks equipped with governors; or hot restart driveaway sag, both governor and non-governor trucks. [355] Low speed driveability or detonation. MAKE CERTAIN THE VEHICLE HAS BEEN UPDATED WITH PREVIOUSLY ATTEMPTED SERVICE FIXES AS FOLLOWS: EGR VALVE P/N 17090156 (STAMPED ON VALVE) 17112373 (GMSPO KIT), PCV VALVE P/N 25098542, ESC MODULE P/N 16175099 (BCC=BARC). [356] Tip-in hesitation, sag, backfire, spark knock. MAKE CERTAIN THE VEHICLE HAS BEEN UPDATED WITH PREVIOUSLY ATTEMPTED SERVICE FIXES AS FOLLOWS: EGR VALVE P/N 17090156 (STAMPED ON VALVE) 17112373 (GMSPO KIT), PCV VALVE P/N 25098542, ESC MODULE P/N 16175099 (BCC=BARC). [357] Hesitation or sag during the first two minutes of cold operation while vehicle is under moderate to heavy throttle driveaway, or TCC chuggle. [358] Sustained detonation/knock. AUTOMATIC TRANSMISSIONS REQUIRE TORQUE CONVERTER CLUTCH (TCC) CALIBRATION. USE OF THIS PROM IN A NON-DETONATING ENGINE MAY RESULT IN DEGRADED DRIVEABILITY. [359] High emissions, exhaust odor, starting and driveability problems (G046). Requires Connector Bleed Assembly P/N 10105820 [360] Neutral gear rattle. MAY ALSO REQUIRE CLUTCH DRIVEN PLATE P/N 15961141, AND CLUTCH PILOT BEARING P/N 14061685. COMBINATION DETONATION AND NEUTRAL GEAR RATTLE PROM AVAILABLE. [361] Malfunction Indicator Lamp (check engine light) illuminates and may set a DTC 24 (VSS Circuit Fault) during a California State Emissions Test. [362] Higher than normal hydrocarbon emissions during the idle portion of the inspection and maintenance test. Also, may exhibit a slight detonation during a light throttle acceleration [363] TCC chuggle. MODEL 2DDM TRANS. - CHECK DEALER RECORDS TO SEE IF THE TORQUE CONVERTER HAS BEEN REPLACED WITH P/N 8650935 (BCC: DGAF). TRANS. WITH TORQUE CONVERTERS WITH P/N 8656959 (BCC: DG5F) NEED TO HAVE THE TORQUE CONVERTER REPLACED WITH P/N 8650935. [364] Cold start stall, cold tip in hesitation and/or a cold rough idle after extended idling. Additionally, in 40-50°F ambient temp., fogging on the inside of the front windshield which does not clear with the defroster on occurs. [365] Poor throttle response, stall, misfire, poor cold or hot start, extended crank of the starter with a hot engine, and/or vehicle will start and then stall when the engine is hot. MT vehicles may also experience decel. stall and poor accel. performance. [366] Poor throttle response, stalling, misfire, poor cold or hot starting, extended cranking of the starter with a hot engine, and/or vehicle will start and then stall when the engine is hot. USED WITH MANUAL TRANSMISSION ONLY. [367] MIL illuminates and/or store a DTC 32 (EGR error) with no noticeable driveability concern, usually occurring while climbing a grade. [368] MIL illuminates and/or store a DTC 32 (EGR error) with no noticeable driveability concern, usually occurring while climbing a grade, towing a trailer or driving into a strong head wind. [369] High emissions, exhaust odor, starting and driveability problems (G046). Requires Connector Bleed Assembly P/N 10105820 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Page 2872 Prom Information Scan Prom Prom Prom Superseding ID Code Bcc Part # ID Part # TSB Reference # 0501 5726 AMXC 16135725 0511 5733 AMXD 16135732 0521 5741 AMXF 16135740 0531 5745 AMXH 16135744 0541 0931 BBYP 16180510 Chevrolet 91-514-7B Engine surge on deceleration. 0551 0936 BBYR 16180512 Chevrolet 91-514-7B Engine surge on deceleration. 0561 0939 BBYS 16180513 Chevrolet 91-514-7B Engine surge on deceleration. 0571 0942 BBYT 16180515 Chevrolet 91-514-7B Engine surge on deceleration. 0581 1082 AUJR 16151080 8321 16158344 0591 1087 AUJS 16151086 8331 16158349 0601 1092 AUJT 16151090 8341 16158354 0611 1097 AUJU 16151096 8351 16158358 2841 3090 AXWF 16163089 Running change. 2851 3095 AXWH 16163094 Running change. 2861 3099 AXWJ 16163098 Running change. 2871 3104 AXWK 16163103 Running change. 3371 3452 BABH 16173383 Chevrolet 91-473-6E Engine chuggle at low speeds. 3381 3455 BABJ 16173384 Chevrolet 91-473-6E Engine chuggle at low speeds. 3391 3458 BABK 16173385 Chevrolet 91-473-6E Engine chuggle at low speeds. 3401 3461 BABL 16173386 Chevrolet 91-473-6E Engine chuggle at low speeds. 4231 4595 ATJJ 16144594 4241 4599 ATJK 16144598 4711 4931 ATKZ 16144604 4721 4934 ATLA 16144605 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Application and ID > Expanded Footnotes > Page 2873 4731 4938 ATLB 16144606 4741 4941 ATLC 16144607 4751 4944 ATLD 16144608 4761 4949 ATLF 16144609 4771 4952 ATLH 16144610 4781 4956 ATLJ 16144612 7401 7677 ATWS 16147673 2841 16163089 7411 7680 ATWT 16147674 2851 16163094 7611 7720 ATXC 16147719 2861 16163098 7621 7724 ATXD 16147723 2871 16163103 8321 8346 AWWM 16158344 Chevrolet 91-222-6E Hesitation or stall on cold acceleration. 8331 8350 AWWN 16158349 Chevrolet 91-222-6E Hesitation or stall on cold acceleration. 8341 8355 AWWP 16158354 Chevrolet 91-222-6E Hesitation or stall on cold acceleration. 8351 8359 AWWR 16158358 Chevrolet 91-222-6E Hesitation or stall on cold acceleration. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Description and Operation > CALPAK PROM - Programmable Read Only Memory: Description and Operation CALPAK CAUTION: If the computer is found to be defective and needs replacement, remove the old CALPAK and PROM, then place both into the replacement computer. When replacing the COMPUTER always transfer the BROADCAST CODE and PRODUCTION ECM/PCM NUMBER to the service label on the replacement computer. DESCRIPTION: The resistor network calibration called a CALPAK is located inside the computer. Its appearance and service is similar to the PROM. The CALPAK allows fuel to be delivered if other parts of the computer fail. The CALPAK provides the computer with calibrations for: ^ Cold Start Cranking. ^ Limp home fuel (fuel backup mode). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Description and Operation > CALPAK > Page 2876 PROM - Programmable Read Only Memory: Description and Operation EEPROM CAUTION: The EEPROM is soldered to the COMPUTER and cannot be serviced separately. Reprogramming of EEPROM information is necessary when replacing a COMPUTER, or when changing the engine and/or transaxle calibrations. Failure to do this will cause the vehicle to have a no start or poor running condition. It is essential that a replacement COMPUTER be reprogrammed with the correct VIN, option content, tire size, and calibration information. Reprogramming of the EEPROM is only possible with the Service Stall System (SSS) hardware available at authorized dealer locations. Check with a dealer before performing COMPUTER replacement or EEPROM reprogramming. DESCRIPTION: The term EEPROM is defined as Electronically Erasable Programmable Read Only Memory (EEPROM) in the COMPUTER. The EEPROM stores vehicle information such as engine and transaxle calibrations, vehicle identification number, programmable vehicle option content and MALF history. Vehicle information stored on the EEPROM has a major effect on how the vehicle will operate. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Description and Operation > CALPAK > Page 2877 PROM - Programmable Read Only Memory: Description and Operation EPROM CAUTION: The EPROM is serviceable in some applications and can be removed for replacement. If the COMPUTER is found to be defective and needs replacement, remove the old EPROM if applicable and place into the new computer. When replacing the COMPUTER always transfer the BROADCAST CODE and PRODUCTION ECM/PCM NUMBER to the service label on the replacement computer. DESCRIPTION: The term EPROM means Erasable Programmable Read Only Memory (EPROM). The EPROM functions in the same manner as a regular PROM and is programmed with data pertaining to the vehicles weight, engine, transmission, axle ratio etc. Automotive technicians do not ERASE or PROGRAM the EPROM in the field. Instead, the EPROM is serviced in one of two manners. Some applications are soldered to the circuit board and require both the computer and EPROM to be replaced as a complete unit. Other applications allow for the EPROM only to replaced. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Description and Operation > CALPAK > Page 2878 PROM - Programmable Read Only Memory: Description and Operation MEMCAL CAUTION: If the COMPUTER is found to be defective and needs replacement, remove the old MEMCAL and place it into the replacement computer. When replacing the COMPUTER always transfer the BROADCAST CODE and PRODUCTION ECM/PCM NUMBER to the service label on the replacement computer. DESCRIPTION: The MEMCAL assembly contains both the functions of the PROM and the CALPAK. Like the PROM, it contains the calibrations needed for a specific vehicle. It also is the fuel back up control for the computer should it become damaged or faulty. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Description and Operation > CALPAK > Page 2879 PROM - Programmable Read Only Memory: Description and Operation PROM CAUTION: If the computer is found to be defective and needs replacement, remove the old PROM and place it into the replacement computer. Some ECM's are equipped with another chip called a CALPAK. If the computer is equipped with a CALPAK chip, it will be located next to the PROM and must be transferred along with the PROM. When replacing the computer always transfer the BROADCAST CODE and PRODUCTION ECM/PCM NUMBER to the service label on the replacement computer. DESCRIPTION: To allow one type of computer to be used for many different vehicles, a device called a Programable Read Only Memory (PROM) unit is used. The PROM is located inside the computer and has system calibration information based upon the vehicle's axle ratio, engine, transmission, weight, and other specific configurations of the vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Description and Operation > Page 2880 PROM - Programmable Read Only Memory: Testing and Inspection Some control modules may have problems due to cracked solder joints on the circuit board. These internal control module problems can cause the following symptoms: ^ Failure to start or vehicle is stalling. ^ The "CHECK ENGINE" "SERVICE ENGINE SOON" or "MALFUNCTION INDICATOR" light will flash or light up, but no trouble codes will be present. ^ Vehicle instrument panel displays may be inoperative. ^ The control module may or may not communicate with the scanner. ^ Other intermittent driveability problems. Incorrect PROM or MEMCAL removal and replacement can create solder joint problems or aggravate an existing condition. See PROM or MEMCAL INSTALLATION for proper procedures. If a solder joint problem results in a "hard" failure, normal test procedures will usually pinpoint a faulty control module. Many symptoms caused by poor solder joints in the control module result in intermittent problems, but they may be hard to duplicate during troubleshooting. Control modules with solder joint problems are sensitive to heat and vibration. You can check for these internal control module problems in either, or both, of the following ways: ^ Remove the control module from its mounting bracket and extend it on the harness so that you can expose it to the vehicle heater ducts. Alternatively, use the flexible duct to route air from the heater to the control module location. Then run the engine and operate the heater at the "MAX HEAT" position. This exposes the control module to approximately 140°F. ^ With the engine running, tap on the control module several times with your hand or finger tips to simulate vehicle vibration. If the engine stumbles or stalls, the "CHECK ENGINE" "SERVICE ENGINE SOON" or "MALFUNCTION INDICATOR" light flashes, or any of the previous symptoms occur, the control module may have bad solder joints on the circuit board. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Service and Repair > CALPAK PROM - Programmable Read Only Memory: Service and Repair CALPAK 1. Remove ECM from vehicle. 2. Remove ECM access cover. 3. Remove Calibration Pack (CALPAK) using removal tool shown. Grasp the CALPAK carrier on the narrow ends only. Gently rock the carrier from end to end while applying a firm upward force. 4. Inspect the reference end of the CALPAK carrier and carefully set aside. Do not remove the CALPAK from the carrier to confirm CALPAK correctness. The notch in the CALPAK is referenced to the small notch in the carrier. The small notch of the carrier must be aligned with the small notch in the socket. CAUTION: ANY TIME THE CALPAK IS INSTALLED BACKWARDS AND THE IGNITION SWITCH IS TURNED ON, THE CALPAK IS DESTROYED. 5. Install the CALPACK by pressing on the CALPAK carrier until it is firmly seated in the socket. Do not press on the CALPAK, only the carrier. 6. Install ECM access cover. 7. Install ECM and perform a DIAGNOSTIC CIRCUIT CHECK to confirm proper installation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Service and Repair > CALPAK > Page 2883 PROM - Programmable Read Only Memory: Service and Repair EEPROM CAUTION: The Erasable Programmable Read Only Memory (EEPROM) is a permanent memory that is physically soldered to the circuit boards within the computer. It is not serviceable and should not be removed for replacement. If COMPUTER replacement is performed, reprogramming of the EEPROM will be necessary. Failure to do this will cause the vehicle to have a no start or poor running condition. Reprogramming of the EEPROM is only possible with the Service Stall System (SSS) hardware available at authorized dealer locations. Check with a dealer before performing COMPUTER replacement or EEPROM reprogramming. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Service and Repair > CALPAK > Page 2884 PROM - Programmable Read Only Memory: Service and Repair EPROM REMOVAL: ^ DO NOT remove an EPROM from its packing material until you are ready to install it. DO NOT hold an EPROM by its pins. ^ Before entering a vehicle to remove or replace an EPROM, touch an exposed metal part of the vehicle to discharge any static charge from your body or use anti-static wrist straps. Avoid sliding across upholstery or carpeting when removing or installing an EPROM. If this is not possible, touch an exposed metal part of the vehicle with your free hand before removing or replacing an EPROM. ^ When available, use an antistatic grounding strap attached to your wrist and clipped to a metal part of the vehicle body to prevent static charges from accumulating. Antistatic conductive floormats are also available. ^ It may be desirable to remove the computer for EPROM replacement. ^ Remove computer access cover. ^ Unlock the locking levers by pressing outward toward the sides of the EPROM. ^ Remove EPROM from its socket INSTALLATION: EPROM/MEM-CAL Unit Installation ^ Install the replacement EPROM in the same direction. ^ VERY GENTLY PRESS down on the ends of the EPROM until the locking levers are rotated toward the sides of the EPROM. ^ NOTE: To avoid Computer damage, do not press on the ends of the EPROM until the levers snap into place. Do not use any vertical force beyond the minimum required to engage the EPROM into its socket. ^ While continuing light pressure on the ends of the EPROM, use your index fingers to press the locking levers inward until they are snapped into place. Listen for the click. ^ Install the access cover on the computer. ^ Perform FUNCTIONAL CHECK Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Service and Repair > CALPAK > Page 2885 PROM - Programmable Read Only Memory: Service and Repair MEMCAL *** UPDATED BY TSB #91-318-6E DATED MAY 1991 CONDITION: When installing a service replacement computer, the use of incorrect MEMCAL installation procedures may cause the computer to fail before it can be installed in the vehicle. This condition may appear as if the computer were defective when shipped to the dealership, when in fact it was damaged while being installed. In addition this condition may also occur when installing an updated MEMCAL into the vehicles original equipment computer. CAUSE: Excessive vertical force may be applied to the MEMCAL resulting in flexing of the circuit board and damage to the connections between the circuit board and attached components. Excessive vertical force may be generated in two ways. ^ Incorrect MEMCAL installation procedures. ^ Interference between MEMCAL and cover. IMPORTANT CORRECTION: This procedure supersedes any instructions regarding MEMCAL installation dated prior to September 1990. 1. Inspect the MEMCAL to determine if a cork spacer is glued to the top side of the MEMCAL assembly. If so, remove it prior to installation. 2. Align small notches with matching notches in Computer MEMCAL socket. 3. VERY GENTLY PRESS down on the ends of the MEMCAL until the locking levers are rotated toward the sides of the MEMCAL. NOTE: To avoid Computer damage, do not press on the ends of the MEMCAL until the levers snap into place. Do not use any vertical force beyond the minimum required to engage the MEMCAL into its socket. 4. While continuing light pressure on the ends of the MEMCAL, use your index fingers to press the locking levers inward until they are snapped into place. Listen for the click. 5. Install MEMCAL cover and install Computer cover. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Service and Repair > CALPAK > Page 2886 PROM - Programmable Read Only Memory: Service and Repair PROM 1. Remove ECM from vehicle. 2. Remove ECM access cover. PROM Removal 3. Remove PROM using the rocker-type PROM removal tool shown. Engage one end of the PROM carrier with the hook end of the tool. Press on the vertical bar end of the tool and rock the engaged end of the PROM carrier up as far as possible. Engage the opposite end of the PROM carrier in the same manner and rock this end up as far as possible. Repeat this process until the PROM carrier and PROM are free of the PROM socket. The PROM carrier with the PROM in it should lift off of the PROM socket easily. 4. Inspect the reference end of the PROM carrier and carefully set aside. Do not remove the PROM from the carrier to confirm PROM correctness. The notch in the PROM is referenced to the small notch in the carrier. The small notch of the carrier must be aligned with the small notch in the socket. CAUTION: ANY TIME THE PROM IS INSTALLED BACKWARDS AND THE IGNITION SWITCH IS TURNED ON, THE PROM IS DESTROYED. 5. Install PROM by pressing on the PROM carrier until it is firmly seated in the socket. Do not press on the PROM, only the carrier. 6. Install ECM access cover. 7. Install ECM and perform a DIAGNOSTIC CIRCUIT CHECK to confirm proper installation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Solenoid To Valve Body ....................................... .............................................................................................................................................................. .8 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 Cover, Auxiliary Valve Body And Pump 3T40 (125C) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 2896 Torque Converter Clutch Solenoid: Description and Operation The purpose of the Transmission Converter Clutch (TCC) feature is to eliminate the power loss of the torque converter stage when the vehicle is in a cruise mode. The TCC System uses a solenoid operated valve to couple the engine flywheel to the output shaft of the transmission through the torque converter. Lockup reduces slippage in the converter increasing fuel economy. For the converter clutch to apply, two conditions must be met: 1. Internal transmission fluid pressure must be correct. 2. The ECM must complete a ground circuit to energize the TCC solenoid which moves a check ball in the fluid line. This allows the converter clutch to apply, when hydraulic pressure is correct. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Service and Repair > Torque Converter Clutch (TCC) Solenoid Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch (TCC) Solenoid TORQUE CONVERTER CLUTCH (TCC) SOLENOID & SWITCHES 3T40 (125C) Auxiliary Valve Body, Valve Body And Oil Pump Assembly Torque Converter Clutch Solenoid & Switches REMOVE OR DISCONNECT 1. Negative battery cable. 2. Raise vehicle and suitably support. 3. Drain fluid. 4. Left front tire and wheel assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 2899 5. Valve body cover. Refer to "Valve Body Cover". 6. Wiring harness from case electrical connector and leads from 3rd clutch pressure switch. 7. Torque converter clutch bolt to auxiliary valve body. 8. 3rd clutch pressure switch. 9. Second clutch switch, if applicable. INSTALL OR CONNECT 1. Second clutch switch, if applicable. TIGHTEN ^ Switch to 11 Nm (8 lb. ft.). 2. 3rd clutch pressure switch. TIGHTEN ^ Switch to 11 Nm (8 lb. ft.). 3. Torque converter clutch bolt to auxiliary valve body. Install new O-ring. TIGHTEN ^ Bolt to 11 Nm (8 lb. ft.). 4. Wire harness to case and switches. 5. Valve body cover with a new gasket. Refer to "Valve Body Cover". 6. Lower vehicle. 7. Negative battery cable. ADJUST ^ T.V. cable. ^ Fluid level. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 2900 Torque Converter Clutch Solenoid: Service and Repair Valve Body Cover VALVE BODY COVER 3T40 (125C) Side Cover And Control Valve View REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Drain oil. 3. Left front tire and wheel assembly. 4. Left splash shield. 5. Valve body cover to transaxle bolts. INSPECT ^ Bolts INSTALL OR CONNECT 1. Valve body cover with a new gasket and bolts. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 2901 Valve Body Cover NOTE: It is necessary to use GM thread locker (P/N 12345382) or equivalent non-locking sealant to reduce the potential for fluid leaks on the indicated bolts. 2. Left splash shield. 3. Left front tire and wheel assembly. 4. Lower vehicle. ADJUST ^ Oil level. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Solenoid To Valve Body ....................................... .............................................................................................................................................................. .8 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Cover, Auxiliary Valve Body And Pump 3T40 (125C) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 2910 Torque Converter Clutch Solenoid: Description and Operation The purpose of the Transmission Converter Clutch (TCC) feature is to eliminate the power loss of the torque converter stage when the vehicle is in a cruise mode. The TCC System uses a solenoid operated valve to couple the engine flywheel to the output shaft of the transmission through the torque converter. Lockup reduces slippage in the converter increasing fuel economy. For the converter clutch to apply, two conditions must be met: 1. Internal transmission fluid pressure must be correct. 2. The ECM must complete a ground circuit to energize the TCC solenoid which moves a check ball in the fluid line. This allows the converter clutch to apply, when hydraulic pressure is correct. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch (TCC) Solenoid TORQUE CONVERTER CLUTCH (TCC) SOLENOID & SWITCHES 3T40 (125C) Auxiliary Valve Body, Valve Body And Oil Pump Assembly Torque Converter Clutch Solenoid & Switches REMOVE OR DISCONNECT 1. Negative battery cable. 2. Raise vehicle and suitably support. 3. Drain fluid. 4. Left front tire and wheel assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 2913 5. Valve body cover. Refer to "Valve Body Cover". 6. Wiring harness from case electrical connector and leads from 3rd clutch pressure switch. 7. Torque converter clutch bolt to auxiliary valve body. 8. 3rd clutch pressure switch. 9. Second clutch switch, if applicable. INSTALL OR CONNECT 1. Second clutch switch, if applicable. TIGHTEN ^ Switch to 11 Nm (8 lb. ft.). 2. 3rd clutch pressure switch. TIGHTEN ^ Switch to 11 Nm (8 lb. ft.). 3. Torque converter clutch bolt to auxiliary valve body. Install new O-ring. TIGHTEN ^ Bolt to 11 Nm (8 lb. ft.). 4. Wire harness to case and switches. 5. Valve body cover with a new gasket. Refer to "Valve Body Cover". 6. Lower vehicle. 7. Negative battery cable. ADJUST ^ T.V. cable. ^ Fluid level. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 2914 Torque Converter Clutch Solenoid: Service and Repair Valve Body Cover VALVE BODY COVER 3T40 (125C) Side Cover And Control Valve View REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Drain oil. 3. Left front tire and wheel assembly. 4. Left splash shield. 5. Valve body cover to transaxle bolts. INSPECT ^ Bolts INSTALL OR CONNECT 1. Valve body cover with a new gasket and bolts. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 2915 Valve Body Cover NOTE: It is necessary to use GM thread locker (P/N 12345382) or equivalent non-locking sealant to reduce the potential for fluid leaks on the indicated bolts. 2. Left splash shield. 3. Left front tire and wheel assembly. 4. Lower vehicle. ADJUST ^ Oil level. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair Band Apply Servo: Service and Repair 1. Remove oil pan and gasket, then remove screen and O-ring. 2. Remove reverse oil pipe retaining brackets, intermediate servo cover and gasket. 3. Remove intermediate servo assembly. 4. Reverse procedure to install. Torque intermediate servo cover screws to 8 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - 3T40 New Side Cover and Bottom Pan Gasket Case: Technical Service Bulletins A/T - 3T40 New Side Cover and Bottom Pan Gasket Number: 91-71-7A Section: 7A Date: September 1990 Corp. Bulletin No.: 077132 Subject: NEW SILICONE BEADED SIDE COVER AND BOTTOM PAN GASKET Model and Year: 1982-90 CELEBRITY, 1982-91 CAVALIER, 1987-91 BERETTA AND CORSICA, 1980-87 CHEVETTE, 1980-85 CITATION 1990-91 U VAN WITH 3T40 AUTOMATIC TRANSMISSION Figure 1 TO: ALL CHEVROLET DEALERS BULLETIN COVERS: A new Side Cover (25) and Bottom Pan (34) gasket for all HYDRA-MATIC 3T40 transaxles, which reduces the potential for Side Cover and/or Bottom Pan leaks. These new gaskets are light gray in color and can be identified by a Silicone Bead which is dark orange in color. (Figure 1) DATE OF PRODUCTION CHANGE: These new Gaskets went into production July 16, 1990 (Julian Date 197) for all Windsor and Willow Run built HYDRA-MATIC 3T40 transaxles. SERVICE PROCEDURE: These new gaskets can be used on all previous model HYDRA-MATIC 3T40 transaxles. Whenever installation or replacement of this new gasket is necessary, refer to the following procedure. SIDE COVER GASKET: 1. Clean ribbed surface of side cover and machined surface of case where gasket is to be installed. Both surfaces MUST be free of transmission fluid. 2. Place side cover gasket on case with silicone bead facing out. 3. Carefully install side cover onto gasket and install all pan bolts (7) by hand. IMPORTANT: The rib on the pan must fully contact the entire silicone bead; if it does not, leakage may occur. 4. Torque all pan bolts to 11 N-m (98 lbs. in.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - 3T40 New Side Cover and Bottom Pan Gasket > Page 2923 BOTTOM PAN GASKET: 1. Clean ribbed surface of bottom pan and machined surface of case where gasket is to be installed. Both surfaces MUST be free of transmission fluid. 2. Place bottom pan gasket on case with silicone bead facing out. 3. Carefully install bottom pan onto gasket and install all pan bolts by hand. IMPORTANT: The rib on the pan must fully contact the entire silicone bead; if it does not, leakage may occur. 4. Torque all pan bolts to 11 N-m (98 lbs. in.). SERVICE PARTS INFORMATION: Whenever ordering this new silicone beaded gasket, refer to the following part numbers: Part Number Description 8678169 Side Cover Gasket 8678168 Bottom Pan Gasket All HYDRA-MATIC 3T40 service packages that contain Side Cover and Bottom Pan gaskets have been updated to include the new Silicone Beaded gaskets. Parts are currently available from GMSPO. SERVICE MANUAL REFERENCE: Whenever replacement and/or installation of a Side Cover or Bottom Pan Gasket on any HYDRA-MATIC 3T40 is necessary, refer to the Unit Repair Section of your Service Manual. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 2924 Case: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Case Cover .......................................................................................................................................... ............................................................................... 18 Case To Drive Sprocket Support .................... .............................................................................................................................................................. ...... 18 Governor Cover To Case ........................................................................................................ .................................................................................... 133 (1) Manual Detent Spring Assembly To Case .................................................................................................................................................... ........................ 8 Neutral Start Switch To Case .................................................................................. ........................................................................................................... 22 Oil Cooler Line To Transaxle Case ................................................................................................................................... ................................................. 16 Parking Lot Bracket To Case ........................................................ ..................................................................................................................................... 18 Pump Cover To Case Cover (6mm) .............................................................................................................. ....................................................................... 8 Pump Cover To Case Cover (8mm) ......................... .......................................................................................................................................................... 18 Reverse Pipe Retainer To Case ..................................................................................................... ..................................................................................... 18 TV Cable To Case .................................... .............................................................................................................................................................. . 75-80 (1) Valve Body To Case .......................................................................................................... ................................................................................................ 18 Valve Body To Case Cover ........... .............................................................................................................................................................. ......................... 8 (1) - Inch Lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 2925 Case: Service and Repair VALVE BODY COVER 3T40 (125C) Side Cover And Control Valve View REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Drain oil. 3. Left front tire and wheel assembly. 4. Left splash shield. 5. Valve body cover to transaxle bolts. INSPECT ^ Bolts INSTALL OR CONNECT 1. Valve body cover with a new gasket and bolts. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 2926 Valve Body Cover NOTE: It is necessary to use GM thread locker (P/N 12345382) or equivalent non-locking sealant to reduce the potential for fluid leaks on the indicated bolts. 2. Left splash shield. 3. Left front tire and wheel assembly. 4. Lower vehicle. ADJUST ^ Oil level. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 2935 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 2936 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-027 > Jun > 08 > A/T No Movement in Drive or 3rd Gear > Page 2942 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-027 > Jun > 08 > A/T No Movement in Drive or 3rd Gear > Page 2943 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 911847A > Feb > 91 > A/T - THM 3T40 New Roller Clutch Clutch: All Technical Service Bulletins A/T - THM 3T40 New Roller Clutch Number: 91-184-7A Section: 7A Date: February 1991 Corporate Bulletin No.: 177103 Subject: NEW ROLLER CLUTCH Model and Year: 1982-91 CELEBRITY, CAVALIER, CORSICA, BERETTA, CHEVETTE, LUMINA AND CITATION WITH 3T60 AUTOMATIC TRANSMISSION Figure 1 Figure 2 BULLETIN COVERS: A new NDH Roller Clutch (662) for all HYDRA-MATIC 3T40 transaxles, for increased Lo Roller clutch durability. This new roller clutch has a new spring and roller holding cage which is plastic and black in color. The springs located inside the roller clutch have been rotated to a position of 90 degrees. (Figures 1 and 2) DATE OF PRODUCTION CHANGE: This new roller clutch went into production October 23, 1990 (Julian Date 296) for all Willow Run built models. Windsor built models will be equipped with this new roller clutch at a future production date. SERVICE PARTS INFORMATION: This new roller clutch may be used in all prior model year HYDRA-MATIC 3T40 transaxles. Whenever ordering this new NDH roller clutch, refer to Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 911847A > Feb > 91 > A/T - THM 3T40 New Roller Clutch > Page 2948 the following part number: Part Number Description 930681 (NDH) Roller Clutch Assembly Parts are currently available from GMSPO. SERVICE MANUAL REFERENCE: Whenever replacement and/or installation of a NDH roller clutch is necessary on any HYDRAMATIC 3T40, refer to the Unit Repair Section of your service manual. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91847A > Oct > 90 > A/T - New Clutch Plates Clutch: All Technical Service Bulletins A/T - New Clutch Plates Number: 91-84-7A Section: 7A Date: October 1990 Corp. Bulletin No.: 077136 Subject: NEW PLATES - 4TH CLUTCH REACTION, FORWARD CLUTCH, LOW AND REVERSE WAVED Model and Year: 1982-90 CELEBRITY, 1982-91 CAVALIER, 1987-91 CORSICA/BERETTA, 1990-91 LUMINA, 1990-91 U VAN (APV) WITH THM F-7, 3T40, 4T60, AND 4T60-E AUTOMATIC TRANSMISSION Figure 1 - New 4th Clutch Plate Assembly TO: ALL CHEVROLET DEALERS BULLETIN COVERS: (Figure 1) New 4th clutch reaction plates for the HYDRA-MATIC 4T60, 4T60-E and THM F-7 transaxles; and new forward clutch and lo and reverse waved plates for the HYDRAMATIC 3T40. All three new plates will have blackened edges, and the flat surfaces will have some lightly blackened areas. The new plates are made with a new process to aid manufacturing. A by-product of this new process is that the edges will be blackened, and the flat surfaces will have some lightly blackened areas. Figure 1 shows an example of a 4th clutch reaction plate with blackened areas and edges. The forward clutch and lo and reverse clutch waved plates will have similar markings. SERVICE PROCEDURE: Replace the 4th clutch reaction plates if severely warped. Replace the 4th clutch reaction plates, forward clutch waved plate, or the lo and reverse waved plates if they have obvious large overheated, discolored areas that mate to the fiber material plate. Heat discoloration on the plate back side (non-fiber mating surfaces) should be considered normal, unless the plate is warped. DATE OF PRODUCTION CHANGE: Beginning July 25, 1990 (Julian Date 206), some 1991 HYDRA-MATIC 4T60, HYDRAMATIC 4T60-E and THM F-7 transaxles were built with the new 4th clutch reaction plates. As of September 10, 1990 (Julian Date 253) all models should have the new reaction plates. Future production changes that will include the new forward clutch and lo and reverse waved plates are scheduled for all 1991 HYDRA-MATIC 3T40 transaxies beginning October 10, 1990 (Julian Date 283). SERVICE PARTS INFORMATION: The new parts will be available when the previous parts are depleted. SERVICE MANUAL REFERENCE: Refer to the appropriate Service Manual for proper disassembly and assembly procedures. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 914131A > Sep > 91 > Heater - Low Output Heater Control Valve: All Technical Service Bulletins Heater - Low Output Number: 91-413-1A Section: 1A Date: SEPT. 1991 Corporate Bulletin No.: 131104 ASE No.: A7 Subject: LOW HEAT DELIVERY RELATED DIAGNOSIS REVISED PROCEDURE Model and Year: 1989-91 CAVALIER On customer comments of low heater output on 1989-91 J cars, before replacing a suspected defective engine cooling thermostat, proper diagnosis of the condition must be performed to avoid the possibility of a repeat repair. Follow "Diagnosis" as shown in Section 1A/1B of the appropriate Service Manual. After completing the diagnosis, use the following as a guide to the next corrective step: ^ If the diagnosis indicates a defective thermostat, refer to Section 6C for replacement. ^ If the diagnosis indicates a defective temperature control cable, refer to Section 1A/1B for replacement. ^ If the diagnosis indicates the temperature control cable is no longer "snapped" into its retainer, refer to "Temperature Control Cable Repair" in the 1991 Service Manual, Sections 1A/1B. ^ If the diagnosis indicates that the temperature control cable is out of adjustment, refer to the following procedure to repair. TEMPERATURE CONTROL CABLE ADJUSTMENT PROCEDURE Condition: 1. "Spring back" off full "hot" temperature control position (or not attaining full "cold" temperature door position). Condition: 2. "Spring back" off full "cold" temperature control position (or not attaining full "hot" temperature door position). Cause: The temperature control cable "clip" needs adjustment. Refer to the illustration for correct gripping of the "clip" during adjustment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 914131A > Sep > 91 > Heater - Low Output > Page 2958 Correction For Number: 1. Grip "clip" at module end of cable while pulling temperature control lever to "hot" position. Correction For Number: 2. Grip "clip" at module end of cable while pushing temperature control lever to "cold" position. NOTICE: FAILURE TO GRIP "CLIP" CORRECTLY WILL DAMAGE ITS ABILITY TO HOLD POSITION ON THE CABLE. THE TEMPERATURE CONTROL CABLE MUST BE REPLACED IF "CLIP" RETENTION FAILS. Verify correct adjustment after repair by observing for no, or very liftle, "spring back" of the temperature control lever and listening for temperature door "slam" when the control lever is moved to full hot and cold positions quickly. Please note your copies of the Service Manuals in Sections 1A and 1B, under "Temperature Control Cable", with these new adjustment instructions. Warranty and Labor Information: Use the appropriate failure code for each occurrence. For thermostat or temperature control cable replacement, use current applicable warranty and labor information. For temperature cable repair at the heater control, use current heater warranty and labor information. For temperature control repair at the HVAC module or cable adjustment: Labor Operation Number: D0400 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 914131A > Sep > 91 > Heater - Low Output > Page 2964 Correction For Number: 1. Grip "clip" at module end of cable while pulling temperature control lever to "hot" position. Correction For Number: 2. Grip "clip" at module end of cable while pushing temperature control lever to "cold" position. NOTICE: FAILURE TO GRIP "CLIP" CORRECTLY WILL DAMAGE ITS ABILITY TO HOLD POSITION ON THE CABLE. THE TEMPERATURE CONTROL CABLE MUST BE REPLACED IF "CLIP" RETENTION FAILS. Verify correct adjustment after repair by observing for no, or very liftle, "spring back" of the temperature control lever and listening for temperature door "slam" when the control lever is moved to full hot and cold positions quickly. Please note your copies of the Service Manuals in Sections 1A and 1B, under "Temperature Control Cable", with these new adjustment instructions. Warranty and Labor Information: Use the appropriate failure code for each occurrence. For thermostat or temperature control cable replacement, use current applicable warranty and labor information. For temperature cable repair at the heater control, use current heater warranty and labor information. For temperature control repair at the HVAC module or cable adjustment: Labor Operation Number: D0400 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Specifications Automatic Transmission Dipstick - Dipstick Tube: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Fill Tube Bolt ........................................................................................................................................ ............................................................................. 31 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 2972 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 2973 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 2974 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 2975 Fluid - A/T: Technical Service Bulletins A/T - DEXRON III Fluid Introduction File In Section: 0 - General Information Bulletin No.: 57-02-01 Date: March, 1995 SERVICE MANUAL UPDATE Subject: Section 0 - General Information - DEXRON(R)-III Transmission Fluid Introduction Models: 1995 and Prior Passenger Cars and Trucks General Motors has phased in a new automatic transmission fluid, DEXRON(R)-III, that does not need replacing under normal service. DEXRON(R)-III is designed to help the transmission deliver the best possible performance under all conditions. Refer to Figure 1. The improvements in DEXRON(R)-III include better friction stability, more high temperature oxidation stability and better material compatibility. DEXRON(R)-III has the same low temperature fluidity as DEXRON(R)-IIE, for better transmission performance in cold weather. DEXRON(R)-IIE and DEXRON(R)-III are fully compatible. DEXRON(R)-III is fully compatible with any General Motors passenger vehicle or light truck with automatic transmission and built since 1949. Dealers should require their supplier to include the DEXRON(R)-III license number on all automatic transmission fluid invoices. Starting February 1, 1994 DEXRON(R)-III was phased into all North American assembly plants. DEXRON(R)-III fluid is available from GMSPO (see fluid numbers below): U.S. 1 Quart 12346143 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 2976 1 Gallon 12346144 55 Gallon 12346145 In Canada 1 Liter 10952622 4 Liter 10952623 200 Liter 10952624 The 1995 Automatic Transmission/Transaxle fluid change intervals are the following: (1994 and prior should use the schedules as written in the Owner's Manual.) 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 car or delivery service. Change the fluid and filter every 50,000 miles (63,000 km). If the vehicle is not used mainly under any of these conditions, the fluid and filter do not require periodic changing for vehicles under 8,600 GVWR. Vehicles over 8,600 GVWR change the fluid and filter every 50,000 miles (83,000 km) regardless of driving conditions. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 2977 Fluid - A/T: Technical Service Bulletins A/T - Fluid Level Checking Procedure Number: 93-98-7A Section: 7A Date: FEB. 1993 Corporate Bulletin No.: 377101 ASE No.: A2 Subject: AUTOMATIC TRANSAXLE FLUID LEVEL CHECKING PROCEDURE Model and Year: 1990 CELEBRITY 1990-93 CAVALIER, CORSICA, BERETTA AND LUMINA 1990-93 LUMINA APV TRANSMISSION APPLICATIONS: 1990-93 HYDRA-MATIC 3T40 (RPO MD9) 1990-93 HYDRA-MATIC 4T60 (RPO ME9) 1991-93 HYDRA-MATIC 4T60-E (RPO M13) 1993 HYDRA-MATIC 4T80-E (RPO MH1) TRANSMISSION MODELS: All SUBJECT: Automatic Transaxle Fluid Level Checking Procedure VEHICLE APPLICATIONS: A, J, L, W Cars AND U-VAN BULLETIN COVERS: Transaxle fluid level checking and condition information. This updates all information previously published for 1990-93 HYDRA-MATIC 3T40, 4T60, 4T60-E and 4T80-E transaxles. Due to enhancement of assembly plant fluid fill capabilities, it is especially important to warm the transaxle up to operating temperature before determining that fluid needs to be added. If the transaxle fluid is close to operating temperature, the fluid level may read slightly below the "ADD" mark. DO NOT ADD FLUID UNLESS THE TRANSAXLE IS AT OPERATING TEMPERATURE AND THE DIPSTICK SHOWS FLUID LEVEL IS BELOW THE CROSSHATCHED AREA. TRANSAXLE FLUID LEVEL INFORMATION: Checking fluid level and condition (color and smell) at recommended service intervals will provide early diagnosis information about the transaxle. This information may then be used to correct a condition that, if not detected early, could result in major transaxle repairs. When adding or changing fluid, use only DEXRON(R)-IIE. Refer to Maintenance and Lubrication (Service Manual Section 0B) for maintenance information and service intervals. NOTICE: Do not overfill. Overfilling will cause foaming, loss of fluid, shift complaints and possible damage to the transaxle. Fluid level should only be checked when it reaches a normal operating temperature of 82-93 degrees C (180-200 degrees F). This temperature is reached after approximately 24 km (15 miles) of driving. TRANSAXLE FLUID COLOR: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 2978 Fluid color will be red when new. IMPORTANT: When new, automatic transaxle fluid is red in color. The red dye is added so the assembly plant can identify it as transaxle fluid and distinguish # from engine oil or antifreeze. The red dye is not an indicator of fluid quality and is not permanent. As the vehicle is driven the fluid will begin to look darker in color. The color may eventually appear light brown. A dark brown color with a burnt odor may indicate fluid deterioration and signal a need for a transaxle fluid change. TRANSAXLE FLUID CHECKING PROCEDURE: 1. Start engine and drive vehicle until the transaxle reaches operating temperature of 82-93 degrees C (180-200 degrees F). This temperature is reached after about 24 km (15 miles) of driving. Inaccurate fluid level readings will result if the fluid level is checked immediately after the vehicle has been operated under certain conditions: - When outside temperatures are above 32 degrees C (90 degrees F) - At sustained high speeds - In heavy city traffic during hot weather - Towing a trailer - In commercial service such as taxi or police use If the vehicle has been operated under any of these conditions, shut the engine off and allow the vehicle to cool for thirty (30) minutes. Then restart the vehicle and continue with step two. 2. Stop vehicle on level ground and put the gear selector in "P" (Park). 3. Set parking brake. 4. With your foot on the brake pedal, move the shift lever through each gear range, pausing for about three seconds in each range. Then put the gear selector back in "P" (Park). 5. Let the engine idle for three to five minutes. 6. Pull out the dipstick and wipe it with a clean rag or towel. 7. Push it back in all the way, wait three seconds and pull it back out. 8. Check both sides of the dipstick and read the lower level. The fluid should be in the crosshatched "HOT" area. IMPORTANT: The fluid level is ok if it is any where within the cross hatched area. It does not have to beat the top of the cross hatched area. Do not add fluid unless the fluid level is below the crosshatched area. 9. If the fluid level is where it should be, push the dipstick back in all the way. ADDING TRANSAXLE FLUID: If fluid level is low (after properly performing the checking procedure above) add only enough fluid to bring the level into the crosshatched area. It doesn't take much fluid, generally less than a pint. Don't overfill. Remember that the level does not need to be at the top of the crosshatched area to be correct. After adding fluid, always recheck the fluid level as described in the above procedure. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications VIN G, Oil Capacity VIN G, Oil Capacity Oil Pan Only 4 qt (US) After Overhaul Less Torque Converter Drain 6 qt (US) With Torque Converter Drain 9 qt (US) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2981 Fluid - A/T: Fluid Type Specifications Lubricant Type ..................................................................................................................................... .................................................................. Dexron II Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 2982 Fluid - A/T: Service and Repair NOTE: Use only Dexron IIE automatic transmission fluid To check fluid, drive vehicle for at least 15 minutes to bring fluid to operating temperature (200°F). With vehicle on a level surface and engine idling in Park and parking brake applied, the level on the dipstick should be at the ``Full'' mark. To bring the fluid level from the ADD mark to the FULL mark requires one pint of fluid. If vehicle cannot be driven sufficiently to bring fluid to operating temperature, the level on the dipstick should be between the two dimples on the dipstick with fluid temperature at 70°F. Note that the two dimples are located above the FULL mark. If additional fluid is required, use only Dexron II automatic transmission fluid. An early change to a darker color from the usual red color and or a strong odor that is usually associated with overheated fluid is normal and should not be considered as a positive sign of required maintenance or unit failure. When adding fluid, do not overfill, as foaming and loss of fluid through the vent may occur as the fluid heats up. Also, if fluid level is too low, complete loss of drive may occur especially when cold, which can cause transmission failure. Every 100,000 miles, the oil should be drained, the oil pan removed, the screen cleaned and fresh fluid added. For vehicles subjected to more severe use such as heavy city traffic especially in hot weather, prolonged periods of idling or towing, this maintenance should be performed every 15,000 miles. 1. Raise and support vehicle, then position drain pan under oil pan. 2. Remove front and side oil pan attaching bolts, then loosen rear pan attaching bolts. 3. Carefully pry oil pan loose from transaxle case and allow fluid to drain. 4. Remove remaining attaching bolt, oil pan and gasket. Thoroughly clean pan before reinstalling. 5. Remove and discard screen and O-ring seal. 6. Install replacement screen and O-ring seal, locating screen against dipstick stop. 7. Install gasket on oil pan, then install pan and torque attaching bolts to 8 ft. lbs. 8. Lower vehicle and add approximately 4 qts. of fluid. 9. With selector in park, parking brake applied and engine at idle speed and operating temperature, check fluid level and add fluid as necessary. Do not race engine. Move shift lever through ranges, then back to ``Park'' position. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > A/T - Transaxle Oil Filter Differences Fluid Filter - A/T: Technical Service Bulletins A/T - Transaxle Oil Filter Differences GROUP REF.: Transmission BULLETIN NO.: 477103 DATE: March, 1994 SUBJECT: TRANSAXLE OIL FILTER DIFFERENCES MODELS: 1985-94 PASSENGER CARS AND U VANS WITH 4T60 OR 4T60-E TRANSAXLES TRANSAXLE APPLICATIONS: HYDRA-MATIC 4T60 (RPO ME9) HYDRA-MATIC 4T60-E (RPO M13) TRANSAXLE MODELS: ALL At the start of the 1993 model year, 4T6O transaxle oil filters were revised in appearance. This revision made the 4T60 transaxle oil filter similar in appearance to the 4T60-E transaxle oil filter. Current and previous design 4T6O transaxle oil filters can be used on any 4T6O transaxle. 4T60 and 4T60-E transaxle oil filters are NOT interchangeable. Refer to the current GMSPO catalog for 4T60 and 4T60-E transaxle oil filter part numbers. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications Cooler Lines At Radiator 20 ft.lb Cooler Lines At Trasaxle 16 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Oil Pan Bolts 133 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Pressure Switch ................................................................................................................................... ................................................................................. 8 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Pump Cover To Valve Body ................................................................................................................ ................................................................................ 8 Pump Cover To Case Cover (6mm) ................ .............................................................................................................................................................. ....... 8 Pump Cover To Case Cover (8mm) ......................................................................................... .......................................................................................... 18 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 912567A > Mar > 91 > A/T - Engine Surge On Deceleration/No Upshift Governor: Customer Interest A/T - Engine Surge On Deceleration/No Upshift Number: 91-256-7A Section: 7A Date: MARCH 1991 Corp. Bulletin No.: 177109 Subject: ENGINE SURGE ON DECELERATION, VEHICLE SPEED ERRATIC WITH CRUISE ON - RANGE OF 1-5 MPH, NO UPSHIFT Model and Year: 1991 CAVALIER, CORSICA, BERETTA, LUMINA WITH 3T40 AUTOMATIC TRANSMISSION BULLETIN COVERS: A new governor assembly (4) which contains a high glass content driven gear. Some owners of 1991 vehicles equipped with HYDRA-MATIC 3T40 transaxles may comment on one or more of the following conditions: - Engine Surge on Deceleration, Surge with Cruise Control Engaged or Vehicle Speed Erratic (range of 1 to 5 MPH). These may be caused by worn teeth (thin) on the governor driven gear. - No Upshift and Stuck in First Gear. These conditions are caused by an applecored governor driven gear. SERVICE PROCEDURE: If any of the above mentioned conditions exist, replace the entire governor assembly with a new high glass content governor, transaxle fluid strainer (33) and seal (32) assembly. This new high glass content governor may be used on transaxles built prior to December 14, 1990 (Julian Date 348). This new high glass content governor driven gear may cause a polished look on the governor drive gear located on the Final Drive (679) but will not affect transaxle durability. SERVICE PARTS INFORMATION: Whenever ordering the new high glass content governor, refer to the following part numbers: Description Model Part Number Governor Assembly AYC 8682985 " " KDC 8682987 " " KXC 8682989 " " LYC 8682991 " " PNC 8682993 " " TRC 8682995 * Each governor package also contains a filter, multi-lip seal and bottom pan gasket. Parts are currently available from GMSPO. SERVICE MANUAL REFERENCE: Refer to the On-Vehicle Service Section of your Service Manual whenever replacement of a governor assembly is necessary. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Governor: > 912567A > Mar > 91 > A/T - Engine Surge On Deceleration/No Upshift Governor: All Technical Service Bulletins A/T - Engine Surge On Deceleration/No Upshift Number: 91-256-7A Section: 7A Date: MARCH 1991 Corp. Bulletin No.: 177109 Subject: ENGINE SURGE ON DECELERATION, VEHICLE SPEED ERRATIC WITH CRUISE ON - RANGE OF 1-5 MPH, NO UPSHIFT Model and Year: 1991 CAVALIER, CORSICA, BERETTA, LUMINA WITH 3T40 AUTOMATIC TRANSMISSION BULLETIN COVERS: A new governor assembly (4) which contains a high glass content driven gear. Some owners of 1991 vehicles equipped with HYDRA-MATIC 3T40 transaxles may comment on one or more of the following conditions: - Engine Surge on Deceleration, Surge with Cruise Control Engaged or Vehicle Speed Erratic (range of 1 to 5 MPH). These may be caused by worn teeth (thin) on the governor driven gear. - No Upshift and Stuck in First Gear. These conditions are caused by an applecored governor driven gear. SERVICE PROCEDURE: If any of the above mentioned conditions exist, replace the entire governor assembly with a new high glass content governor, transaxle fluid strainer (33) and seal (32) assembly. This new high glass content governor may be used on transaxles built prior to December 14, 1990 (Julian Date 348). This new high glass content governor driven gear may cause a polished look on the governor drive gear located on the Final Drive (679) but will not affect transaxle durability. SERVICE PARTS INFORMATION: Whenever ordering the new high glass content governor, refer to the following part numbers: Description Model Part Number Governor Assembly AYC 8682985 " " KDC 8682987 " " KXC 8682989 " " LYC 8682991 " " PNC 8682993 " " TRC 8682995 * Each governor package also contains a filter, multi-lip seal and bottom pan gasket. Parts are currently available from GMSPO. SERVICE MANUAL REFERENCE: Refer to the On-Vehicle Service Section of your Service Manual whenever replacement of a governor assembly is necessary. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Governor: > 177109 > Mar > 91 > A/T - 3T40 Governor Failure Updated Part Governor: All Technical Service Bulletins A/T - 3T40 Governor Failure Updated Part BULLETIN NO.: 9173T40-02 CORP.REF.NO.: 177109 DATE: March 1991 TRANSAXLE APPLICATIONS: 1991 HYDRA-MATIC 3T40 Transaxle TRANSAXLE MODELS: AYC, KDC, KXC, LYC, PNC, TRC SUBJECT: Idle RPM Surge on Deceleration and/or Cruise Control Speed Fluctuation and/or Vehicle Speed Erratic (1-5 MPH). No Upshift. (Applecored or Worn Governor Driven Gear) VEHICLE APPLICATIONS: J, L, N and W-Cars BULLETIN COVERS: A new governor assembly (4) which contains a High Glass content driven gear. Some owners of 1991 vehicles equipped with HYDRA-MATIC 3T40 transaxles may comment on one or more of the following conditions: ^ Engine Surge on Deceleration, Surge with Cruise Control engaged or Vehicle Speed Erratic (range 1-5 MPH). These may be caused by worn teeth (thin) on the governor driven gear. ^ No upshift and Stuck in First gear. These conditions are caused by an applecored governor driven gear. SERVICE ACTION: If any of the above mentioned conditions exist, replace the entire governor assembly with a New High Glass content governor, transaxle fluid strainer (33) and seal (32) assembly. This New High Glass content Governor may be used on transaxles built prior to December 14, 1990 (Julian Date 348). This New High Glass content governor driven gear may cause a polished look on the governor drive gear located on the Final Drive (679) but will not affect transaxle durability. SERVICE PARTS INFORMATION: Whenever ordering the New High Glass Content governor refer to the following part number: DESCRIPTION MODEL AND PART NUMBER Governor Assembly AYC 8682985 Governor Assembly KDC 8682987 Governor Assembly KXC 8682989 Governor Assembly LYC 8682991 Governor Assembly PNC 8682993 Governor Assembly TRC 8682995 * Each governor package also contains a filter multi-lip seal and bottom pan gasket. Parts are currently available from GMSPO. SERVICE MANUAL REFERENCE: Refer to the On-Vehicle Service Section of your Service Manual whenever replacement of a governor assembly is necessary. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Governor: > 177109 > Mar > 91 > A/T - 3T40 Governor Failure Updated Part Governor: All Technical Service Bulletins A/T - 3T40 Governor Failure Updated Part BULLETIN NO.: 9173T40-02 CORP.REF.NO.: 177109 DATE: March 1991 TRANSAXLE APPLICATIONS: 1991 HYDRA-MATIC 3T40 Transaxle TRANSAXLE MODELS: AYC, KDC, KXC, LYC, PNC, TRC SUBJECT: Idle RPM Surge on Deceleration and/or Cruise Control Speed Fluctuation and/or Vehicle Speed Erratic (1-5 MPH). No Upshift. (Applecored or Worn Governor Driven Gear) VEHICLE APPLICATIONS: J, L, N and W-Cars BULLETIN COVERS: A new governor assembly (4) which contains a High Glass content driven gear. Some owners of 1991 vehicles equipped with HYDRA-MATIC 3T40 transaxles may comment on one or more of the following conditions: ^ Engine Surge on Deceleration, Surge with Cruise Control engaged or Vehicle Speed Erratic (range 1-5 MPH). These may be caused by worn teeth (thin) on the governor driven gear. ^ No upshift and Stuck in First gear. These conditions are caused by an applecored governor driven gear. SERVICE ACTION: If any of the above mentioned conditions exist, replace the entire governor assembly with a New High Glass content governor, transaxle fluid strainer (33) and seal (32) assembly. This New High Glass content Governor may be used on transaxles built prior to December 14, 1990 (Julian Date 348). This New High Glass content governor driven gear may cause a polished look on the governor drive gear located on the Final Drive (679) but will not affect transaxle durability. SERVICE PARTS INFORMATION: Whenever ordering the New High Glass Content governor refer to the following part number: DESCRIPTION MODEL AND PART NUMBER Governor Assembly AYC 8682985 Governor Assembly KDC 8682987 Governor Assembly KXC 8682989 Governor Assembly LYC 8682991 Governor Assembly PNC 8682993 Governor Assembly TRC 8682995 * Each governor package also contains a filter multi-lip seal and bottom pan gasket. Parts are currently available from GMSPO. SERVICE MANUAL REFERENCE: Refer to the On-Vehicle Service Section of your Service Manual whenever replacement of a governor assembly is necessary. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Page 3021 Governor: Specifications COMPONENT ..................................................................................................................................... ...................................................... Torque/In.Lbs. Governor Cover To Case ..................................... ............................................................................................................................................................ 133 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Page 3022 Governor: Service and Repair Fig. 12 Removing & Installing Governor Assembly 1. Raise and support vehicle. 2. Remove engine to transaxle brace attaching bolts, then the heat shield, if equipped. 3. Remove speedometer cable or wire connector from transaxle. 4. Remove speedometer driven gear and sleeve assembly or speed sensor, as equipped. 5. Remove governor cover and O-ring. 6. Remove speedometer drive gear thrust washer and gear, then the governor assembly, Fig. 12. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > Customer Interest for A/T Shift Indicator Module: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned A/T Shift Indicator Module: Customer Interest A/T - Shift Indicator Misaligned Number: 91-458-7A Section: 7A Date: DEC. 1991 Corporate Bulletin No.: 138305 ASE No.: A2 Subject: SHIFT INDICATOR MISALIGNED Model and Year: 1991 CAVALIER WITH AUTOMATIC TRANSMISSION Condition: Shift indicator may come out of adjustment. Cause: Adjuster did not "collapse" on indicator tape during production, thus creating a low ratcheting effort. Correction: Replace console trim plate with updated part. Refer to "Parts Information" for updated part number. Refer to Section 8C for replacement procedure. Parts Information: 22575236 Trim plate assembly - with power windows 22575237 Trim plate assembly - without power windows Parts are currently available from GMSPO. Warranty Information: Labor Operation Number: K5100 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/T Shift Indicator Module: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned A/T Shift Indicator Module: All Technical Service Bulletins A/T - Shift Indicator Misaligned Number: 91-458-7A Section: 7A Date: DEC. 1991 Corporate Bulletin No.: 138305 ASE No.: A2 Subject: SHIFT INDICATOR MISALIGNED Model and Year: 1991 CAVALIER WITH AUTOMATIC TRANSMISSION Condition: Shift indicator may come out of adjustment. Cause: Adjuster did not "collapse" on indicator tape during production, thus creating a low ratcheting effort. Correction: Replace console trim plate with updated part. Refer to "Parts Information" for updated part number. Refer to Section 8C for replacement procedure. Parts Information: 22575236 Trim plate assembly - with power windows 22575237 Trim plate assembly - without power windows Parts are currently available from GMSPO. Warranty Information: Labor Operation Number: K5100 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Parking Lock Cable: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking Parking Lock Cable: Customer Interest Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Parking Lock Cable: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3050 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Parking Lock Cable: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3051 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Parking Lock Cable: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3052 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Parking Lock Cable: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3053 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Parking Lock Cable: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3054 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Parking Lock Cable: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3055 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Lock Cable: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking Parking Lock Cable: All Technical Service Bulletins Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Lock Cable: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3061 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Lock Cable: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3062 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Lock Cable: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3063 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Lock Cable: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3064 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Lock Cable: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3065 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Lock Cable: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3066 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > A/T - 3T40 New Side Cover and Bottom Pan Gasket Seals and Gaskets: Technical Service Bulletins A/T - 3T40 New Side Cover and Bottom Pan Gasket Number: 91-71-7A Section: 7A Date: September 1990 Corp. Bulletin No.: 077132 Subject: NEW SILICONE BEADED SIDE COVER AND BOTTOM PAN GASKET Model and Year: 1982-90 CELEBRITY, 1982-91 CAVALIER, 1987-91 BERETTA AND CORSICA, 1980-87 CHEVETTE, 1980-85 CITATION 1990-91 U VAN WITH 3T40 AUTOMATIC TRANSMISSION Figure 1 TO: ALL CHEVROLET DEALERS BULLETIN COVERS: A new Side Cover (25) and Bottom Pan (34) gasket for all HYDRA-MATIC 3T40 transaxles, which reduces the potential for Side Cover and/or Bottom Pan leaks. These new gaskets are light gray in color and can be identified by a Silicone Bead which is dark orange in color. (Figure 1) DATE OF PRODUCTION CHANGE: These new Gaskets went into production July 16, 1990 (Julian Date 197) for all Windsor and Willow Run built HYDRA-MATIC 3T40 transaxles. SERVICE PROCEDURE: These new gaskets can be used on all previous model HYDRA-MATIC 3T40 transaxles. Whenever installation or replacement of this new gasket is necessary, refer to the following procedure. SIDE COVER GASKET: 1. Clean ribbed surface of side cover and machined surface of case where gasket is to be installed. Both surfaces MUST be free of transmission fluid. 2. Place side cover gasket on case with silicone bead facing out. 3. Carefully install side cover onto gasket and install all pan bolts (7) by hand. IMPORTANT: The rib on the pan must fully contact the entire silicone bead; if it does not, leakage may occur. 4. Torque all pan bolts to 11 N-m (98 lbs. in.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > A/T - 3T40 New Side Cover and Bottom Pan Gasket > Page 3075 BOTTOM PAN GASKET: 1. Clean ribbed surface of bottom pan and machined surface of case where gasket is to be installed. Both surfaces MUST be free of transmission fluid. 2. Place bottom pan gasket on case with silicone bead facing out. 3. Carefully install bottom pan onto gasket and install all pan bolts by hand. IMPORTANT: The rib on the pan must fully contact the entire silicone bead; if it does not, leakage may occur. 4. Torque all pan bolts to 11 N-m (98 lbs. in.). SERVICE PARTS INFORMATION: Whenever ordering this new silicone beaded gasket, refer to the following part numbers: Part Number Description 8678169 Side Cover Gasket 8678168 Bottom Pan Gasket All HYDRA-MATIC 3T40 service packages that contain Side Cover and Bottom Pan gaskets have been updated to include the new Silicone Beaded gaskets. Parts are currently available from GMSPO. SERVICE MANUAL REFERENCE: Whenever replacement and/or installation of a Side Cover or Bottom Pan Gasket on any HYDRA-MATIC 3T40 is necessary, refer to the Unit Repair Section of your Service Manual. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Specifications Fluid Pressure Sensor/Switch: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Pressure Switch ................................................................................................................................... ................................................................................. 8 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Rear Of 3.1L Rear Of Engine, Top LH Side Of Transaxle Applicable to: 1L/V6-192 Engine. Cavalier w/Automatic Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3083 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch & Connector The PARK/NEUTRAL switch indicates to the computer when the transmission is in park or neutral. This information is used by the computer for ignition timing, Idle Air Control (IAC), and Transmission Torque Converter Clutch (TCC) operation. DO NOT drive the vehicle with the PARK/NEUTRAL switch disconnected, since idle quality may be affected. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3084 Transmission Position Switch/Sensor: Testing and Inspection Chart C-1A Wiring Diagram For P/N Switch CIRCUIT DESCRIPTION: The PARK/NEUTRAL switch contacts are closed to ground in park or neutral and open in drive ranges. The ECM supplies ignition voltage through a current limiting resistor to circuit 434, and senses a closed switch when the voltage on circuit 434 drops to less than one volt. The ECM uses the P/N signal as one of the inputs to control idle air and vehicle speed sensor diagnostics. TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3085 1. Checks for a closed switch to ground in the PARK position. Different makes of "Scan" tools will read PARK/NEUTRAL differently. Refer to operators manual for type of display used for a specific tool. 2. Checks for an open switch in drive range. 3. Be sure the "Scan" tool indicates drive even while wiggling the shifter to test for an intermittent or misadjusted switch in drive. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3086 Transmission Position Switch/Sensor: Adjustments 1. Place transaxle shift lever in NEUTRAL. 2. Loosen switch attaching screws. 3. Rotate switch on shaft assembly to align service adjustment hole with carrier tang hole. a. Insert 2.34 mm (3/32 inch) maximum diameter gauge pin to a depth of 15.0 mm (5/8 inch). 4. Tighten attaching screws. See SPECIFICATIONS/MECHANICAL for torque values. 5. Remove the gauge pin. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3087 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Start and Backup Lamp Switch 1. Remove negative battery cable, shift linkage, electrical connector, mounting bolts, and switch assembly. 2. Replacement using old or new switch. a. Place shift shaft in NEUTRAL. b. Align flats of shift shaft with switch. c. Old Switch only - Install mounting bolts-to-case, loosely. Insert gauge pin in service adjustment hole, and rotate switch until pin drops into a depth of 9.0 mm (9/64") and tighten bolts (see SPECIFICATIONS/MECHANICAL for torque values). d. New Switch only - Install mounting bolts and tighten. If bolt holes do not align with mounting boss on transaxle, verify that the shift shaft is in NEUTRAL; DO NOT rotate the switch. The switch is pinned in the NEUTRAL position. NOTE: If the switch has been rotated and the pin is broken, the switch can be adjusted using the old switch procedure and ADJUSTMENT PROCEDURES. 3. See ADJUSTMENT PROCEDURES for PARK/NEUTRAL switch adjustment. 4. After the switch is installed, verify that the engine will start only in PARK (A/T) or NEUTRAL (M/T). If the engine starts in any other position, readjust the switch using old switch procedure and ADJUSTMENT PROCEDURES. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Electronic Speed Sensor Retainer ...................................................................................................... ...................................................................... 7 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Solenoid To Valve Body ....................................... .............................................................................................................................................................. .8 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications > Shift Lever to Shift Cable Shifter A/T: Specifications Shift Cable To Shift Lever 90 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications > Shift Lever to Shift Cable > Page 3098 Shifter A/T: Specifications Transaxle Control Lever COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Transaxle Control Lever ...................................................................................................................... .............................................................................. 15 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications Shift Cable: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Shift Cable Bracket Bolts ..................................................................................................................... .............................................................................. 20 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Specifications Speedometer Gear, A/T: Specifications COMPONENT ..................................................................................................................................... ...................................................... Torque/In.Lbs. Speedometer Driven Gear To Governor Cover ................................................................................... ............................................................................... 75 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Specifications Throttle Valve Cable/Linkage: Specifications COMPONENT ..................................................................................................................................... ...................................................... Torque/In.Lbs. TV Cable To Case ............................................................................................................................... ......................................................................... 75-80 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Specifications > Page 3109 Throttle Valve Cable/Linkage: Adjustments Fig. 8 Downshift Cable Adjustment. Except 1989-90 Models w/2.0L/4-121 Overhead Cam Engine Fig. 9 Downshift Cable Adjustment. 1989-90 Models w/2.0L/4-121 Overhead Cam Engine 1. Depress and hold metal lock tab, Figs. 8 and 9. 2. Move slider back through fitting in direction away from throttle idler lever until slider stops against fitting, then release lock tab. 3. Rotate throttle idler lever to full travel stop position to set automatic cable adjuster on cable to correct setting, then release throttle idler lever. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Torque Converter Bolts 46 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch: > 92427A > Nov > 91 > A/T - Intermittent Slip, Downshift, or Busy Cycling TCC Torque Converter Clutch: Customer Interest A/T - Intermittent Slip, Downshift, or Busy Cycling TCC Number: 92-42-7A Section: 7A Date: NOV. 1991 Corporate Bulletin No.: 167105 ASE No.: A2 Subject: INTERMITTENT TRANSMISSION DOWNSHIFT, SLIP OR BUSY/CYCLING TCC Model and Year: 1983-92 ALL PASSENGER CARS AND TRUCKS WITH AUTOMATIC TRANSMISSION Some owners may comment that their vehicle is experiencing one or more of the following transmission conditions: - Intermittent slipping. - Intermittent downshift followed by an upshift, both with no apparent reason. - Busyness or cycling of the TCC at steady throttle conditions and level roadway. The cooling fan operates when the thermostat on the fan clutch reaches a preset temperature. When this temperature is reached, the fan engages to draw additional air through the radiator and lower the engine temperature. When the cooling fan engages, noise increases and may sound very similar to an increase in engine RPM due to transmission downshift, slipping or TCC cycling. When engine temperature lowers to a preset point the fan clutch will disengage. When the cooling fan disengages, noise levels will decrease and may sound very similar to a decrease in engine RPM. The type of concern described above requires further definition and the customer should be asked several questions: - Is the situation more pronounced at higher vehicle loads or pulling a trailer? - Do warmer ambient temperatures make the situation more pronounced as well? If the customer's responses indicate that both of these conditions apply, and your observation of the vehicle confirms a properly operating vehicle, provide the customer the vehicle operating description included in this bulletin. Further action may not be necessary. A service procedure follows if further definition is required. SERVICE PROCEDURE: When attempting to diagnose an intermittent transmission downshift, slip or busy/cycling TCC: 1. Check fluid level and condition as outlined in section 7A of the appropriate service manual. 2. Test drive the vehicle under the conditions described by the customer (ambient temperature, engine coolant temperature, trailering, etc.). It may be necessary to partially restrict airflow to the radiator to raise engine coolant temperature to match customer conditions. 3. Monitor engine RPM and engine coolant temperature using a scan tool. 4. Listen for an apparent increase in engine RPM. If engine RPM sounds like it increases, check the scan tool RPM and coolant temperature readings. If the noise increase is due to engagement of the fan the engine RPM will not increase and engine coolant temperature will begin to decrease after the fan engages. As the fan runs the engine coolant temperature will drop and the fan will disengage reducing noise levels, engine RPM will not decrease. This cycle will repeat as engine coolant temperature again rises. If the above procedure shows the condition to be cooling fan related, no further action is necessary. The vehicle should be returned to the customer and the condition explained. If the above procedure shows the condition to be other than cooling fan related, refer to section 7A of the appropriate service manual for transmission diagnosis information. Intermittent Transmission Downshift All light duty trucks are equipped with a thermostatic engine cooling fan. This fan is designed to provide greater fuel efficiency and quieter operation Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch: > 92427A > Nov > 91 > A/T - Intermittent Slip, Downshift, or Busy Cycling TCC > Page 3121 than a standard fan. These benefits are possible through the addition of a thermostatic clutch to the fan drive. When the engine is cool the clutch allows the fan to "slip" or turn at a speed slower than the engine. By turning at a slower speed the fan uses less horsepower, which saves fuel, and is quieter. When the engine temperature reaches a preset temperature, the fan "engages" and turns at the same speed as the engine. "Engagement" of the fan provides increased airflow through the radiator to cool the engine. As the airflow increases, fan operation becomes clearly audible. This increase in noise can easily be mistaken for an increase in engine RPM and may be incorrectly blamed on the automatic transmission. When operating an unloaded vehicle in cooler ambient temperatures, the thermostatic clutch usually won't engage. However, if the vehicle is pulling a trailer, heavily loaded or operated at high ambient temperatures the thermostatic clutch may cycle on and off as the engine temperature rises and falls. The sound of fan operation under the conditions described above is a sign that the cooling system on your vehicle is working correctly. Replacement or modification of cooling system or transmission parts will not change or reduce the noise level. Attempts to reduce this noise will only give you, the customer, a false sense of vehicle unreliability and the inconvenience of having your vehicle out of service. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch: > 92427A > Nov > 91 > A/T - Intermittent Slip, Downshift, or Busy Cycling TCC Torque Converter Clutch: All Technical Service Bulletins A/T - Intermittent Slip, Downshift, or Busy Cycling TCC Number: 92-42-7A Section: 7A Date: NOV. 1991 Corporate Bulletin No.: 167105 ASE No.: A2 Subject: INTERMITTENT TRANSMISSION DOWNSHIFT, SLIP OR BUSY/CYCLING TCC Model and Year: 1983-92 ALL PASSENGER CARS AND TRUCKS WITH AUTOMATIC TRANSMISSION Some owners may comment that their vehicle is experiencing one or more of the following transmission conditions: - Intermittent slipping. - Intermittent downshift followed by an upshift, both with no apparent reason. - Busyness or cycling of the TCC at steady throttle conditions and level roadway. The cooling fan operates when the thermostat on the fan clutch reaches a preset temperature. When this temperature is reached, the fan engages to draw additional air through the radiator and lower the engine temperature. When the cooling fan engages, noise increases and may sound very similar to an increase in engine RPM due to transmission downshift, slipping or TCC cycling. When engine temperature lowers to a preset point the fan clutch will disengage. When the cooling fan disengages, noise levels will decrease and may sound very similar to a decrease in engine RPM. The type of concern described above requires further definition and the customer should be asked several questions: - Is the situation more pronounced at higher vehicle loads or pulling a trailer? - Do warmer ambient temperatures make the situation more pronounced as well? If the customer's responses indicate that both of these conditions apply, and your observation of the vehicle confirms a properly operating vehicle, provide the customer the vehicle operating description included in this bulletin. Further action may not be necessary. A service procedure follows if further definition is required. SERVICE PROCEDURE: When attempting to diagnose an intermittent transmission downshift, slip or busy/cycling TCC: 1. Check fluid level and condition as outlined in section 7A of the appropriate service manual. 2. Test drive the vehicle under the conditions described by the customer (ambient temperature, engine coolant temperature, trailering, etc.). It may be necessary to partially restrict airflow to the radiator to raise engine coolant temperature to match customer conditions. 3. Monitor engine RPM and engine coolant temperature using a scan tool. 4. Listen for an apparent increase in engine RPM. If engine RPM sounds like it increases, check the scan tool RPM and coolant temperature readings. If the noise increase is due to engagement of the fan the engine RPM will not increase and engine coolant temperature will begin to decrease after the fan engages. As the fan runs the engine coolant temperature will drop and the fan will disengage reducing noise levels, engine RPM will not decrease. This cycle will repeat as engine coolant temperature again rises. If the above procedure shows the condition to be cooling fan related, no further action is necessary. The vehicle should be returned to the customer and the condition explained. If the above procedure shows the condition to be other than cooling fan related, refer to section 7A of the appropriate service manual for transmission diagnosis information. Intermittent Transmission Downshift All light duty trucks are equipped with a thermostatic engine cooling fan. This fan is designed to provide greater fuel efficiency and quieter operation Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch: > 92427A > Nov > 91 > A/T - Intermittent Slip, Downshift, or Busy Cycling TCC > Page 3127 than a standard fan. These benefits are possible through the addition of a thermostatic clutch to the fan drive. When the engine is cool the clutch allows the fan to "slip" or turn at a speed slower than the engine. By turning at a slower speed the fan uses less horsepower, which saves fuel, and is quieter. When the engine temperature reaches a preset temperature, the fan "engages" and turns at the same speed as the engine. "Engagement" of the fan provides increased airflow through the radiator to cool the engine. As the airflow increases, fan operation becomes clearly audible. This increase in noise can easily be mistaken for an increase in engine RPM and may be incorrectly blamed on the automatic transmission. When operating an unloaded vehicle in cooler ambient temperatures, the thermostatic clutch usually won't engage. However, if the vehicle is pulling a trailer, heavily loaded or operated at high ambient temperatures the thermostatic clutch may cycle on and off as the engine temperature rises and falls. The sound of fan operation under the conditions described above is a sign that the cooling system on your vehicle is working correctly. Replacement or modification of cooling system or transmission parts will not change or reduce the noise level. Attempts to reduce this noise will only give you, the customer, a false sense of vehicle unreliability and the inconvenience of having your vehicle out of service. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Page 3128 Torque Converter Clutch: Testing and Inspection Chart C-8A Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Page 3129 Wiring Diagram For TCC CIRCUIT DESCRIPTION: The purpose of the automatic transmission Torque Converter Clutch (TCC) feature is to eliminate the power loss of the torque converter when the vehicle is in a cruise mode. This allows the convenience of the automatic transmission and the fuel economy of a manual transmission. Fused ignition voltage is supplied to the TCC solenoid through the brake and third gear switches. The ECM will engage the TCC by grounding circuit 422 to energize the solenoid. The TCC will engage when the following conditions exist: 1. Vehicle speed above 23 mph (37 km/h) with A/C "OFF" (35 mph with A/C "ON"). 2. Engine coolant temperature exceeds 30°C (86°F). 3. Throttle position sensor output is not changing faster than a calibrated rate (steady throttle). 4. Transaxle third gear switch closed. 5. Brake switch closed. TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. 1. Light "OFF" confirms transaxle third gear apply switch is open. 2. At 30 mph (48 km/h), the transaxle third gear switch should close. A test light will illuminate and confirm battery supply, and close the brake switch. 3. Grounding the diagnostic terminal with the engine "OFF" should energize the TCC solenoid. This checks the capability of the ECM to control the solenoid. DIAGNOSTIC AIDS: An engine coolant thermostat which is stuck open or opens at a low temperature may result in an inoperative TCC. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Cover, Auxiliary Valve Body And Pump 3T40 (125C) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3133 Torque Converter Clutch Solenoid: Description and Operation The purpose of the Transmission Converter Clutch (TCC) feature is to eliminate the power loss of the torque converter stage when the vehicle is in a cruise mode. The TCC System uses a solenoid operated valve to couple the engine flywheel to the output shaft of the transmission through the torque converter. Lockup reduces slippage in the converter increasing fuel economy. For the converter clutch to apply, two conditions must be met: 1. Internal transmission fluid pressure must be correct. 2. The ECM must complete a ground circuit to energize the TCC solenoid which moves a check ball in the fluid line. This allows the converter clutch to apply, when hydraulic pressure is correct. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch (TCC) Solenoid TORQUE CONVERTER CLUTCH (TCC) SOLENOID & SWITCHES 3T40 (125C) Auxiliary Valve Body, Valve Body And Oil Pump Assembly Torque Converter Clutch Solenoid & Switches REMOVE OR DISCONNECT 1. Negative battery cable. 2. Raise vehicle and suitably support. 3. Drain fluid. 4. Left front tire and wheel assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 3136 5. Valve body cover. Refer to "Valve Body Cover". 6. Wiring harness from case electrical connector and leads from 3rd clutch pressure switch. 7. Torque converter clutch bolt to auxiliary valve body. 8. 3rd clutch pressure switch. 9. Second clutch switch, if applicable. INSTALL OR CONNECT 1. Second clutch switch, if applicable. TIGHTEN ^ Switch to 11 Nm (8 lb. ft.). 2. 3rd clutch pressure switch. TIGHTEN ^ Switch to 11 Nm (8 lb. ft.). 3. Torque converter clutch bolt to auxiliary valve body. Install new O-ring. TIGHTEN ^ Bolt to 11 Nm (8 lb. ft.). 4. Wire harness to case and switches. 5. Valve body cover with a new gasket. Refer to "Valve Body Cover". 6. Lower vehicle. 7. Negative battery cable. ADJUST ^ T.V. cable. ^ Fluid level. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 3137 Torque Converter Clutch Solenoid: Service and Repair Valve Body Cover VALVE BODY COVER 3T40 (125C) Side Cover And Control Valve View REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Drain oil. 3. Left front tire and wheel assembly. 4. Left splash shield. 5. Valve body cover to transaxle bolts. INSPECT ^ Bolts INSTALL OR CONNECT 1. Valve body cover with a new gasket and bolts. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 3138 Valve Body Cover NOTE: It is necessary to use GM thread locker (P/N 12345382) or equivalent non-locking sealant to reduce the potential for fluid leaks on the indicated bolts. 2. Left splash shield. 3. Left front tire and wheel assembly. 4. Lower vehicle. ADJUST ^ Oil level. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 3143 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 3144 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 3145 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 3146 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 3147 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 3148 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 91448A7A > Jan > 92 > Transaxle Mount - Chirps Transmission Mount: Customer Interest Transaxle Mount - Chirps REVISED Number: 91-448A-7A Section: 7A Date: JAN 1992 Corporate Bulletin No.: 137108 ASE No.: A2, A3 Subject: TRANSAXLE MOUNT CHIRPS Model and Year: 1990-91 CAVALIER, CORSICA BERETTA WITH 2.2L AND 3.1L ENGINES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-448-7A. DATED NOV. 1991. THE 1990-91 2.2L MR7 MANUAL TRANSMISSION HAS BEEN ADDED. ALL COPIES OF 91-448-7A SHOULD BE DISCARDED. Condition: Chirping noise in engine compartment. Cause: Transaxle mount bumper rubs against mount. Correction: Replace transaxle mount bumper with new bumper. Refer to "Parts Information" for vehicle application and updated part number. IMPORTANT: Before transaxle mount bumper is replaced, be sure the bumper is the source of the noise. Coat the bumper with a silicone base grease and test drive vehicle. If noise is no longer evident, replace the bumper. 1. Remove transaxle mount from the vehicle. Refer to appropriate Service Manual and Section for procedure. 2. Place the mount in a vise. Refer to Figure 1. 3. Remove bumper retaining nuts (if not removed during transaxle mount removal). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 91448A7A > Jan > 92 > Transaxle Mount - Chirps > Page 3157 4. Remove bumper. Lift up on the inner mount assembly until the bumper can be removed. Refer to Figure 2. 5. Install new bumper by lifting up on inner mount assembly. 6. Install bumper retaining nuts. 7. Remove mount from vise. 8. Install transaxle mount in the vehicle. Parts Information: Model VIN Car Bumper Year Break Line Engine Transaxle Part Number 1990-91 M7242459 J 2.2L MR7 - Manual 22575852 1990-91 M7242459 J 2.2L 3T40 - Auto 22575853 1990-91 M7242459 J 3.1L MD9 - Auto 22575854 1990-91 M7242459 J 3.1L MG2 - Manual 22575855 1990-91 MY192128 L 2.2L MD9 - Auto 22575853 ME062328 1990-91 MY207010 L ALL MR3 - Manual 22577700 ME063635 Model VIN Car Bumper Year Break Line Engine Transaxle Part Number 1990-91 MY192201 L 3.1L MD9 - Auto 22577701 ME061493 1990-91 MY202773 L 3.1L MG2 - Manual 22577699 ME064089 Parts are currently available from GMSPO. Labor Operation Number: T1790 Labor Time: .8 Hour for 4 cylinder engines with Automatic or Manual Transmission 1.0 Hour for 6 cylinder engines with Automatic or Manual Transmission Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 91448A7A > Jan > 92 > Transaxle Mount - Chirps > Page 3158 Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 91448A7A > Jan > 92 > Transaxle Mount - Chirps Transmission Mount: All Technical Service Bulletins Transaxle Mount - Chirps REVISED Number: 91-448A-7A Section: 7A Date: JAN 1992 Corporate Bulletin No.: 137108 ASE No.: A2, A3 Subject: TRANSAXLE MOUNT CHIRPS Model and Year: 1990-91 CAVALIER, CORSICA BERETTA WITH 2.2L AND 3.1L ENGINES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-448-7A. DATED NOV. 1991. THE 1990-91 2.2L MR7 MANUAL TRANSMISSION HAS BEEN ADDED. ALL COPIES OF 91-448-7A SHOULD BE DISCARDED. Condition: Chirping noise in engine compartment. Cause: Transaxle mount bumper rubs against mount. Correction: Replace transaxle mount bumper with new bumper. Refer to "Parts Information" for vehicle application and updated part number. IMPORTANT: Before transaxle mount bumper is replaced, be sure the bumper is the source of the noise. Coat the bumper with a silicone base grease and test drive vehicle. If noise is no longer evident, replace the bumper. 1. Remove transaxle mount from the vehicle. Refer to appropriate Service Manual and Section for procedure. 2. Place the mount in a vise. Refer to Figure 1. 3. Remove bumper retaining nuts (if not removed during transaxle mount removal). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 91448A7A > Jan > 92 > Transaxle Mount - Chirps > Page 3164 4. Remove bumper. Lift up on the inner mount assembly until the bumper can be removed. Refer to Figure 2. 5. Install new bumper by lifting up on inner mount assembly. 6. Install bumper retaining nuts. 7. Remove mount from vise. 8. Install transaxle mount in the vehicle. Parts Information: Model VIN Car Bumper Year Break Line Engine Transaxle Part Number 1990-91 M7242459 J 2.2L MR7 - Manual 22575852 1990-91 M7242459 J 2.2L 3T40 - Auto 22575853 1990-91 M7242459 J 3.1L MD9 - Auto 22575854 1990-91 M7242459 J 3.1L MG2 - Manual 22575855 1990-91 MY192128 L 2.2L MD9 - Auto 22575853 ME062328 1990-91 MY207010 L ALL MR3 - Manual 22577700 ME063635 Model VIN Car Bumper Year Break Line Engine Transaxle Part Number 1990-91 MY192201 L 3.1L MD9 - Auto 22577701 ME061493 1990-91 MY202773 L 3.1L MG2 - Manual 22577699 ME064089 Parts are currently available from GMSPO. Labor Operation Number: T1790 Labor Time: .8 Hour for 4 cylinder engines with Automatic or Manual Transmission 1.0 Hour for 6 cylinder engines with Automatic or Manual Transmission Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 91448A7A > Jan > 92 > Transaxle Mount - Chirps > Page 3165 Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 3166 Transmission Mount: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Transaxle Mount Pipe Expansion Bolt ................................................................................................. .............................................................................. 41 Transaxle Mount Support Brace Nuts ............. .............................................................................................................................................................. ..... 18 Transaxle Mount Through Bolts ............................................................................................... ......................................................................................... 82 Transaxle Mount To Support Bolts ....... .............................................................................................................................................................. ............... 49 Transaxle Mount To Transaxle Bolts .............................................................................. ................................................................................................... 41 Transaxle To Engine Mount Bolts ..................................................................................................................................................... ................................ 55 Transaxle Support Assembly Bolts ................................................................ .................................................................................................................... 55 Engine Mount Bolts ... .............................................................................................................................................................. .......................................... 34 Frame Insulator Bolts .......................................................................... ............................................................................................................................... 40 Frame To Crossmember Bolts ............................................................................................................................. ............................................................... 37 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Rear Of 3.1L Rear Of Engine, Top LH Side Of Transaxle Applicable to: 1L/V6-192 Engine. Cavalier w/Automatic Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3170 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch & Connector The PARK/NEUTRAL switch indicates to the computer when the transmission is in park or neutral. This information is used by the computer for ignition timing, Idle Air Control (IAC), and Transmission Torque Converter Clutch (TCC) operation. DO NOT drive the vehicle with the PARK/NEUTRAL switch disconnected, since idle quality may be affected. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3171 Transmission Position Switch/Sensor: Testing and Inspection Chart C-1A Wiring Diagram For P/N Switch CIRCUIT DESCRIPTION: The PARK/NEUTRAL switch contacts are closed to ground in park or neutral and open in drive ranges. The ECM supplies ignition voltage through a current limiting resistor to circuit 434, and senses a closed switch when the voltage on circuit 434 drops to less than one volt. The ECM uses the P/N signal as one of the inputs to control idle air and vehicle speed sensor diagnostics. TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3172 1. Checks for a closed switch to ground in the PARK position. Different makes of "Scan" tools will read PARK/NEUTRAL differently. Refer to operators manual for type of display used for a specific tool. 2. Checks for an open switch in drive range. 3. Be sure the "Scan" tool indicates drive even while wiggling the shifter to test for an intermittent or misadjusted switch in drive. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3173 Transmission Position Switch/Sensor: Adjustments 1. Place transaxle shift lever in NEUTRAL. 2. Loosen switch attaching screws. 3. Rotate switch on shaft assembly to align service adjustment hole with carrier tang hole. a. Insert 2.34 mm (3/32 inch) maximum diameter gauge pin to a depth of 15.0 mm (5/8 inch). 4. Tighten attaching screws. See SPECIFICATIONS/MECHANICAL for torque values. 5. Remove the gauge pin. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3174 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Start and Backup Lamp Switch 1. Remove negative battery cable, shift linkage, electrical connector, mounting bolts, and switch assembly. 2. Replacement using old or new switch. a. Place shift shaft in NEUTRAL. b. Align flats of shift shaft with switch. c. Old Switch only - Install mounting bolts-to-case, loosely. Insert gauge pin in service adjustment hole, and rotate switch until pin drops into a depth of 9.0 mm (9/64") and tighten bolts (see SPECIFICATIONS/MECHANICAL for torque values). d. New Switch only - Install mounting bolts and tighten. If bolt holes do not align with mounting boss on transaxle, verify that the shift shaft is in NEUTRAL; DO NOT rotate the switch. The switch is pinned in the NEUTRAL position. NOTE: If the switch has been rotated and the pin is broken, the switch can be adjusted using the old switch procedure and ADJUSTMENT PROCEDURES. 3. See ADJUSTMENT PROCEDURES for PARK/NEUTRAL switch adjustment. 4. After the switch is installed, verify that the engine will start only in PARK (A/T) or NEUTRAL (M/T). If the engine starts in any other position, readjust the switch using old switch procedure and ADJUSTMENT PROCEDURES. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Specifications Transmission Pressure Test Port: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Line Pressure Take-Off ....................................................................................................................... ................................................................................. 8 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Electronic Speed Sensor Retainer ...................................................................................................... ...................................................................... 7 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - Evaluating Peened Spacer Plates Valve Body: Technical Service Bulletins A/T - Evaluating Peened Spacer Plates Number: 91-396-7A Section: 7A Date: AUGUST 1991 Corporate Bulletin No.: 177120 Subject: EVALUATING PEENED SPACER PLATES Model and Year: 1982-91 ALL PASSENGER CARS AND TRUCKS WITH AUTOMATIC TRANSAXLES AND TRANSMISSIONS (EXCEPT GEO) TRANSMISSIONS APPLICATIONS: All HYDRA-MATIC Automatic Transmissions and Transaxles SUBJECT: Evaluating Peened Spacer Plates (Service Information) TRANSMISSION MODELS: All VEHICLE APPLICATIONS: All Vehicles Using HYDRA-MATIC Automatic Transmissions and Transaxles Bulletin Covers: Some spacer plate peening is considered acceptable and preferred because it can help seat the check ball. This bulletin will help you decide if a spacer plate needs to be replaced due to a peening condition. Service Procedure: The following two procedures can help determine if the spacer plate can be reused. The following must be performed at all check-ball locations. Figure 1 1. The spacer plate must be inspected 100% for raised material on the opposite side of the check-ball seat (see Figure 1). If the material on the opposite side is raised, the peening is too severe and the spacer plate must be replaced. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - Evaluating Peened Spacer Plates > Page 3185 Figure 2 2. To verify that the spacer plate is peening evenly and the ball is sealing correctly, seat the check-ball on the spacer plate. Shine a beam of light on the opposite side and inspect for light between the spacer plate and check-ball (see Figure 2). No trace of light should be present. If light can be seen, a proper seal does not exist, and the spacer plate must be replaced. Service Manual Reference: Refer to the HYDRA-MATIC Automatic Transaxle/Transmission Diagnosis or Unit Repair section of your service manual for proper check-ball locations and functions. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 3186 Valve Body: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Valve Body Cover Bolts ....................................................................................................................... ...................................................................... 124 (1) Valve Body To Driven Sprocket Support .......... .............................................................................................................................................................. .. 18 Valve Body To Case .................................................................................................................... ...................................................................................... 18 Valve Body To Case Cover ..................... .............................................................................................................................................................. ............... 8 (1) - Inch Lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Checkball Locations 3T40 (125C) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Checkball Locations > Page 3189 Cover, Auxiliary Valve Body And Pump 3T40 (125C) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Page 3190 Valve Body: Service and Repair AUXILIARY VALVE BODY, VALVE BODY & OIL PUMP ASSEMBLY 3T40 (125C) Fig. 11 Valve Body & Auxiliary Valve Body Retaining Screws 1. Remove valve body cover and gasket. 2. Remove solenoid retaining bolt and the solenoid, then disconnect converter clutch wires from 3rd gear pressure switch. 3. Remove screws attaching throttle lever and bracket assembly, then remove throttle lever and bracket assembly with T.V. cable link. 4. Remove the auxiliary valve body screws except for the one screw shown in Fig. 11. Loosen, but do not remove, this screw. 5. Remove remaining valve body retaining screws, then the valve body and pump assembly. 6. Separate valve body from auxiliary valve body. 7. Reverse procedure to install. Torque all 6 mm bolts to 8 ft. lbs. and all 8 mm bolts to 18 ft. lbs. 8. Using new gasket, install valve body cover to transaxle and torque bolts to 12 ft. lbs. Transaxle valve body covers and oil pans can have a raised rib, depressed rib or flat sealing flange. RTV sealant should be used on all oil pans and valve body covers that have a flat sealing flange. Gaskets should be used on all oil pans and valve body covers that have either depressed or raised rib sealing flanges. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications Fill the clutch master cylinder to the "Full" or "MAX" mark on the reservoir. Do not overfill. Caution: Should accidental spillage occur, rinse the area thoroughly with water. Pay special attention to any electrical wires, parts, harnesses, rubber or painted surfaces. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 3197 Clutch Fluid: Fluid Type Specifications Hydraulic Clutch Fluid ........................................................................................................................................ GM P/N 12345347 or DOT 3 Brake Fluid Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > With GM-Isuzu 5 Speed Manual Transaxle Clutch Master Cylinder: Specifications With GM-Isuzu 5 Speed Manual Transaxle Clutch Master Cylinder Retaining Bolts ........................................................................................................................................................... 15-25 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > With GM-Isuzu 5 Speed Manual Transaxle > Page 3202 Clutch Master Cylinder: Specifications Without GM-Isuzu 5 Speed Manual Transaxle Clutch Master Cylinder To Front Of Dash .............................................................................................................................................................. 16 ft. lbs. Actuator Cylinder ................................................................................................................. ................................................................................... 16 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Bleeding Hydraulic System Clutch Master Cylinder: Service and Repair Bleeding Hydraulic System Preliminary Information CLUTCH HYDRAULIC SYSTEM The clutch hydraulic system is serviced as a complete unit and has been bled of air and filled with fluid. Individual components of the system are not available separetely. Bleeding Hydraulic System Bleeding is necessary whenever the level of fluid in the reservoir has been allowed to fall so low that air has been drawn into the master cylinder. NOTICE: Never, under any circumstances, use fluid which has been bled from a system to fill the reservoir as it may be aerated, have too much moisture content and possibly be contaminated. Bleeding Procedure With Bleed Screw Bleeding Procedure With Bleed Screw 1. Remove the cap and diaphragm. Clean ^ Dirt and grease from the cap to ensure that no foreign substances enter the system. 2. Fill reservoir to top step with Delco Supreme No. II(R) fluid GM P/N 1052535: Hydraulic Clutch Fluid GM P/N 12345347 or equivalent that meets DOT 3 specifications. 3. Fully loosen the bleed screw on the actuator cylinder body next to the inlet connection. Important ^ For efficient gravity fill, the reservoir must be kept full at all times. Tighten ^ Bleed screw to 2 N.m (17 lbs. in.) when a steady stream of fluid comes from the bleed screw. 4. Install the diaphragm and cap to reservoir. Inspect ^ Fluid level in reservoir 5. Fill reservoir with Delco Supreme No. II(R) fluid GM P/N 1052535 or equivalent DOT 3 fluid. 6. Start the engine and push the clutch to the floor. Wait ten seconds and select reverse gear. There should be no grating of gears. If there is, the hydraulic system may still contain air. If this is the condition, repeat bleeding procedure. Bleeding Procedure Without Bleed Screw Bleeding Procedure Without Bleed Screw 1. Remove the hydraulic actuator cylinder from the transaxle. 2. Loosen the clutch master cylinder mounting nuts to the ends of the studs. Do not remove the master cylinder. 3. Remove the reservoir cap and diaphragm. Clean ^ Dirt and grease from the cap to ensure no foreign substances will enter the system. Measure ^ Depress hydraulic actuator cylinder pushrod approximately 20.0 mm (0.787 in.) into the actuator cylinder bore and hold. 4. Install the diaphragm and cap on the reservoir while holding actuator cylinder pushrod in as described. 5. Release the actuator cylinder pushrod. 6. Hold the actuator cylinder vertically with the pushrod end facing down. Important ^ Actuator cylinder should be lower than the master cylinder. 7. Press the pushrod into the actuator cylinder bore with short 10.0 mm (0.390 in.) strokes. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Bleeding Hydraulic System > Page 3205 Inspect ^ Reservoir for air bubbles 8. Continue until air bubbles are no longer entering the reservoir. 9. Install the actuator cylinder on the transaxle 10. Install the clutch master cylinder mounting nuts Tighten ^ Nuts evenly to 21 N.m (16 lbs. ft.). Inspect ^ Fluid level in reservoir. Fill reservoir with Delco Supreme No. II(R) fluid or equivalent DOT 3 fluid. 11. Start the engine and push the clutch to the floor. Wait ten seconds and select reverse gear. There should be no grating of gears. If so, hydraulic system may still contain air. If this is the condition, repeat bleeding procedure. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Bleeding Hydraulic System > Page 3206 Clutch Master Cylinder: Service and Repair Removal and Installation REMOVAL 1. Disconnect negative battery cable. 2. Remove sound insulator from inside of vehicle. 3. Disconnect clutch master cylinder push rod from clutch pedal. 4. Remove clutch master cylinder retaining nuts at front of dash and disconnect remote reservoir, if equipped. 5. Remove actuator retaining nuts at transaxle. 6. Remove hydraulic system as a unit from vehicle. INSTALLATION 1. Install actuator cylinder to transaxle support bracket aligning pushrod into pocket on lever. Torque nuts evenly to 16 ft. lbs. 2. Install clutch master cylinder to front of dash. Torque nuts evenly to 16 ft. lbs. Do not remove plastic pushrod retainer from actuator cylinder. Retainer will break off on first clutch pedal application. 3. Connect remote reservoir, if equipped. 4. Remove pedal restrictor from pushrod, then lubricate push rod bushing on clutch pedal. 5. Connect push rod with clutch pedal and install retaining clip. 6. Install sound insulator. 7. Press clutch pedal down several times. This will break plastic retaining straps on actuator cylinder push rod. Do not remove plastic button on pushrod. 8. Connect negative battery cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Bleeding Hydraulic System > Page 3207 Clutch Master Cylinder: Service and Repair Clutch Master & Actuator Cylinders Removal 1. Disconnect negative battery cable. 2. Remove sound insulator from inside of vehicle. 3. Disconnect clutch master cylinder pushrod from clutch pedal. 4. Remove clutch master cylinder retaining nuts at front of dash and disconnect remote reservoir, if equipped. 5. Remove actuator retaining nuts at transaxle. 6. Remove hydraulic system as a unit from vehicle. Installation 1. Install actuator cylinder to transaxle support bracket aligning pushrod into pocket on lever. Torque nuts evenly to 16 ft. lbs. 2. Install clutch master cylinder to front of dash. Torque nuts evenly to 16 ft. lbs. Do not remove plastic pushrod retainer from actuator cylinder. Retainer will break off on first clutch pedal application. 3. Connect remote reservoir, if equipped. 4. Remove pedal restrictor from pushrod, then lubricate pushrod bushing on clutch pedal. 5. Connect pushrod with clutch pedal and install retaining clip. 6. Install sound insulator. 7. Press clutch pedal down several times. This will break plastic retaining straps on actuator cylinder pushrod. Do not remove plastic button on pushrod. 8. Connect negative battery cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > HM-282 and 5TM40 Clutch Slave Cylinder: Specifications HM-282 and 5TM40 Clutch Cylinder Stud ............................................................................................................................ .................................................................. 23 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > HM-282 and 5TM40 > Page 3212 Clutch Slave Cylinder: Specifications GM-Isuzu 5 Speed Manual Transaxle Slave Cylinder Retaining Nuts ............................................................................................................. ............................................................. 14-20 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Bleeding Hydraulic System Clutch Slave Cylinder: Service and Repair Bleeding Hydraulic System Preliminary Information CLUTCH HYDRAULIC SYSTEM The clutch hydraulic system is serviced as a complete unit and has been bled of air and filled with fluid. Individual components of the system are not available separetely. Bleeding Hydraulic System Bleeding is necessary whenever the level of fluid in the reservoir has been allowed to fall so low that air has been drawn into the master cylinder. NOTICE: Never, under any circumstances, use fluid which has been bled from a system to fill the reservoir as it may be aerated, have too much moisture content and possibly be contaminated. Bleeding Procedure With Bleed Screw Bleeding Procedure With Bleed Screw 1. Remove the cap and diaphragm. Clean ^ Dirt and grease from the cap to ensure that no foreign substances enter the system. 2. Fill reservoir to top step with Delco Supreme No. II(R) fluid GM P/N 1052535: Hydraulic Clutch Fluid GM P/N 12345347 or equivalent that meets DOT 3 specifications. 3. Fully loosen the bleed screw on the actuator cylinder body next to the inlet connection. Important ^ For efficient gravity fill, the reservoir must be kept full at all times. Tighten ^ Bleed screw to 2 N.m (17 lbs. in.) when a steady stream of fluid comes from the bleed screw. 4. Install the diaphragm and cap to reservoir. Inspect ^ Fluid level in reservoir 5. Fill reservoir with Delco Supreme No. II(R) fluid GM P/N 1052535 or equivalent DOT 3 fluid. 6. Start the engine and push the clutch to the floor. Wait ten seconds and select reverse gear. There should be no grating of gears. If there is, the hydraulic system may still contain air. If this is the condition, repeat bleeding procedure. Bleeding Procedure Without Bleed Screw Bleeding Procedure Without Bleed Screw 1. Remove the hydraulic actuator cylinder from the transaxle. 2. Loosen the clutch master cylinder mounting nuts to the ends of the studs. Do not remove the master cylinder. 3. Remove the reservoir cap and diaphragm. Clean ^ Dirt and grease from the cap to ensure no foreign substances will enter the system. Measure ^ Depress hydraulic actuator cylinder pushrod approximately 20.0 mm (0.787 in.) into the actuator cylinder bore and hold. 4. Install the diaphragm and cap on the reservoir while holding actuator cylinder pushrod in as described. 5. Release the actuator cylinder pushrod. 6. Hold the actuator cylinder vertically with the pushrod end facing down. Important ^ Actuator cylinder should be lower than the master cylinder. 7. Press the pushrod into the actuator cylinder bore with short 10.0 mm (0.390 in.) strokes. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Bleeding Hydraulic System > Page 3215 Inspect ^ Reservoir for air bubbles 8. Continue until air bubbles are no longer entering the reservoir. 9. Install the actuator cylinder on the transaxle 10. Install the clutch master cylinder mounting nuts Tighten ^ Nuts evenly to 21 N.m (16 lbs. ft.). Inspect ^ Fluid level in reservoir. Fill reservoir with Delco Supreme No. II(R) fluid or equivalent DOT 3 fluid. 11. Start the engine and push the clutch to the floor. Wait ten seconds and select reverse gear. There should be no grating of gears. If so, hydraulic system may still contain air. If this is the condition, repeat bleeding procedure. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Bleeding Hydraulic System > Page 3216 Clutch Slave Cylinder: Service and Repair Clutch Master & Actuator Cylinder Removal 1. Disconnect negative battery cable. 2. Remove sound insulator from inside of vehicle. 3. Disconnect clutch master cylinder pushrod from clutch pedal. 4. Remove clutch master cylinder retaining nuts at front of dash and disconnect remote reservoir, if equipped. 5. Remove actuator retaining nuts at transaxle. 6. Remove hydraulic system as a unit from vehicle. Installation 1. Install actuator cylinder to transaxle support bracket aligning pushrod into pocket on lever. Torque nuts evenly to 16 ft. lbs. 2. Install clutch master cylinder to front of dash. Torque nuts evenly to 16 ft. lbs. Do not remove plastic pushrod retainer from actuator cylinder. Retainer will break off on first clutch pedal application. 3. Connect remote reservoir, if equipped. 4. Remove pedal restrictor from pushrod, then lubricate pushrod bushing on clutch pedal. 5. Connect pushrod with clutch pedal and install retaining clip. 6. Install sound insulator. 7. Press clutch pedal down several times. This will break plastic retaining straps on actuator cylinder pushrod. Do not remove plastic button on pushrod. 8. Connect negative battery cable. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Linkage > Component Information > Specifications Clutch Linkage: Specifications Clutch Shaft Release Lever Bolt .......................................................................................................... ............................................................. 30-45 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Adjustments Clutch Pedal Assembly: Adjustments Figure 1 Figure 2 On these models, a hydraulic clutch system is used, Fig. 1 and 2. The system consists of a dash mounted master cylinder with integral reservoir, a transmission mounted slave cylinder and high pressure tubing to connect the two components. The hydraulic clutch system provides automatic clutch adjustment, therefore, there is no provision for adjustment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Start Switch <--> [Clutch Switch] > Component Information > Locations Clutch Start Switch: Locations Below LH Side Of I/P. Behind I/P, On Clutch Pedal Support Applicable to: 1991 Cavalier w/Manual Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Start Switch <--> [Clutch Switch] > Component Information > Locations > Page 3226 Clutch Start Switch: Service and Repair 1. Disconnect clutch switch electrical connector. 2. Remove clutch bracket and switch attaching nuts, then remove switch. 3. Reverse procedure to install. Torque switch attaching nuts to 53 inch lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Specifications Clutch Release Fork: Specifications Clutch Shaft Release Lever Bolt .......................................................................................................... ............................................................. 30-45 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Clutch Cover To Flywheel 22 ft.lb Note: Plus 30 Degree turn. Clutch Cover To Transaxle 115 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON Continuously Variable Transmission/Transaxle: 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON > Page 3241 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-06-01-029E > Apr > 10 > Vehicle - Engine Crankcase and Subsystems Flushing Info. Continuously Variable Transmission/Transaxle: All Technical Service Bulletins Vehicle - Engine Crankcase and Subsystems Flushing Info. INFORMATION Bulletin No.: 04-06-01-029E Date: April 29, 2010 Subject: Unnecessary Flushing Services, Additive Recommendations and Proper Utilization of GM Simplified Maintenance Schedule to Enhance Customer Service Experience Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add information about the proper transmission flush procedure. Please discard Corporate Bulletin Number 04-06-01-029D (Section 06 - Engine/Propulsion System). An Overview of Proper Vehicle Service General Motors is aware that some companies are marketing tools and equipment to support a subsystem flushing procedures. These dedicated machines are in addition to many engine oil, cooling system, fuel system, A/C, transmission flush and steering system additives available to the consumer. GM Vehicles under normal usage do not require any additional procedures or additives beyond what is advised under the former Vehicle Maintenance Schedules or the current Simplified Maintenance Schedules. Do not confuse machines available from Kent-Moore/SPX that are designed to aid and accelerate the process of fluid changing with these flushing machines. Engine Crankcase Flushing General Motors Corporation does not endorse or recommend engine crankcase flushing for any of its gasoline engines. Analysis of some of the aftermarket materials used for crankcase flushing indicate incompatibility with GM engine components and the potential for damage to some engine seals and bearings. Damage to engine components resulting from crankcase flushing IS NOT COVERED under the terms of the New Vehicle Warranty. GM Authorized Service Information: Detailed, Descriptive, and Complete If a specific model vehicle or powertrain need is identified, GM will issue an Authorized Service Document containing a procedure and, if required, provide, make available, or require the specific use of a machine, tool or chemical to accomplish proper vehicle servicing. An example of this is fuel injector cleaning. Due to variation in fuel quality in different areas of the country, GM has recognized the need for fuel injector cleaning methods on some engines, though under normal circumstances, this service is not part of the maintenance requirements. GM has published several gasoline fuel injector cleaning bulletins that fully outline the methods to be used in conjunction with GM Part Numbered solutions to accomplish proper and safe cleaning of the fuel injectors with preventative maintenance suggestions to maintain optimum performance. You may refer to Corporate Bulletin Numbers 03-06-04-030 and 04-06-04-051 for additional information on this subject. Subsystem Flushing Flushing of A/C lines, radiators, transmission coolers, and power steering systems are recognized practices to be performed after catastrophic failures or extreme corrosion when encountered in radiators. For acceptable A/C flushing concerns, refer to Corporate Bulletin Number 01-01-38-006. This practice is NOT required or recommended for normal service operations. The use of external transmission fluid exchange or flush machines is NOT recommended for the automatic or manual transmission. Use of external machines to replace the fluid may affect the operation or durability of the transmission. Transmission fluid should only be replaced by draining and refilling following directions in SI. Refer to Automatic/Manual Transmission Fluid and Filter Replacement. Approved Transmission Flushing Tool (Transmission Cooler Only) The Automatic Transmission Oil Cooler Flush and Flow Test Tool is recommended for GM vehicles. Refer to Transmission Fluid Cooler Flushing and Flow Test in SI using the J 45096. Service Is Important to You and Your Customer General Motors takes great pride in offering our dealerships and customers high quality vehicles that require extremely low maintenance over the life of the vehicle. This low cost of ownership builds repeat sales and offers our customers measurable economy of operation against competing vehicles. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-06-01-029E > Apr > 10 > Vehicle - Engine Crankcase and Subsystems Flushing Info. > Page 3247 Providing responsible services at the proper intervals will greatly aid your dealership with repeat business, and additional services when required. Most customers appreciate and gain trust in the dealership that informs and offers them just what they need for continued trouble-free operation. Examine your service department's practices and verify that all Service Consultants and Technicians focus on customer satisfaction, vehicle inspections, and other products at time of service. Use this opportunity to upgrade the services you provide to your customers. Here are a few suggestions: - Take the time required to align your dealership service practices with the new GM Simplified Maintenance Schedule. Use the new vehicle Owner's Manual Maintenance I and II schedules to create a "mirror image" in your advertising and dealer service pricing that is easily understandable to your customer. Taking advantage of this new service strategy may greatly increase your dealership service sales and customer retention while decreasing the frequency of visits and inconvenience to your customer. - Review your program to ensure that all vehicles coming in are evaluated for safety and wear items. Examine all vehicles for tire condition, signs of misalignment, brake wear, exterior lamp functionality, exhaust condition, A/C cooling performance, SRS or Air Bag MIL, along with Service Engine Soon or Check Engine indicators. If the Service Engine Soon or Check Engine MIL is illuminated, it is vital that you inform the customer of the concerns with ignoring the indicator and what the required repair would cost. In addition to the possibility of increased emissions and driveability concerns, many customers are unaware that lower gas mileage may also result, with additional cost to the customer. - Be complete in your service recommendations. Some sales opportunities are not being fully pursued nationally. Focus on overlooked but required maintenance that has real benefits to the customer. Many vehicles are equipped with cabin air filters. If these filters are used beyond replacement time, they may impede airflow decreasing A/C and heating performance. Make sure these filters are part of your recommended service. Note that some of our vehicles may not have been factory equipped but will accept the filters as an accessory. - Express the value in maintaining the finish quality of the customer's vehicle at the Maintenance I and II visits. More fully utilize the vehicle prep personnel you already have in place. In today's world, many people simply ignore the finish of their vehicle, at best infrequently using an automatic car wash for exterior cleaning. Offer vehicle detailing services in stages from just a wash and wax to a complete interior cleaning. When paired with the Simplified Maintenance visit, this will increase customer satisfaction. On return, the customer gets a visibly improved vehicle that will be a source of pride of ownership along with a vehicle that is now fully maintained. Also, reinforce the improved resale value of a completely maintained vehicle. - For customers who clean and maintain the appearance of their vehicles themselves encourage the use of GM Vehicle Care products. Many customers may have never used GM Car Wash/Wax Concentrate, GM Cleaner Wax or a longtime product, GM Glass Cleaner, which is a favorite of many customers who try it just once. If your dealership give samples of these products with new car purchases, customers may already be sold on the product but not willing to make a special trip to the dealership. Capitalize on sales at this time. Stock shelves right at the Service counter with these products and consider instituting compensation programs for Service Consultants who suggest these products. Many consumers faced with an intimidating wall full of car care products sold at local auto parts stores may find it comforting to purchase a fully tested product sold by GM that they know will not harm the finish of their vehicle. We suggest these competitively priced basic vehicle care products to emphasize: In USA: - #12378401 GM Vehicle Care Wash/Wax Concentrate 16 fl. oz. (0.473L) - #89021822 GM Vehicle Care Glass Cleaner Aerosol 18 oz. (510 g) - #12377966 GM Vehicle Care Cleaner Wax 16 fl. oz. (0.473L) - #1052929 GM Vehicle Care Chrome and Wire Wheel Cleaner 16 fl. oz. (0.473L) - #88861431 GM Vehicle Care Odor Eliminator 24 fl. oz. (0.710L) In Canada: - #10953203 GM Vehicle Care Wash & Wax Concentrate 473 mL - #992727 GM Glass Cleaner Aerosol 500 g - #10952905 GM Vehicle Care Liquid Cleaner/Wax 473 mL - #10953013 GM Vehicle Care Chrome Cleaner and Polish 454 mL - #10953202 GM Vehicle Care Wheel Brite 473 mL - #88901678 GM Vehicle Care Odor Eliminator 473 mL - Display signboards with the installed price for popular GM Accessories such as running boards and Tonneau Covers. Customers may not think to ask about these desirable items at the time of a service visit. - Finally, take advantage of the GM Goodwrench initiatives (Tire Program, Goodwrench Credit Card, etc. / Dealer Marketing Association (DMA) Promotions in Canada) to provide the customer with more reasons to identify your dealership as the best place to go for parts and service. Remember to utilize ALL of the service aspects you possess in your dealership to satisfy and provide value to your customer. Many businesses exist profitably as an oil change location, a vehicle repair facility, or a detailing shop alone. You already have the capabilities of all three and provide these services with the inherent trust of your customer, under the GM Mark of Excellence. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Continuously Variable Transmission/Transaxle: 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3252 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > All Other Service Bulletins for Continuously Variable Transmission/Transaxle: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned A/T Shift Indicator Module: All Technical Service Bulletins A/T - Shift Indicator Misaligned Number: 91-458-7A Section: 7A Date: DEC. 1991 Corporate Bulletin No.: 138305 ASE No.: A2 Subject: SHIFT INDICATOR MISALIGNED Model and Year: 1991 CAVALIER WITH AUTOMATIC TRANSMISSION Condition: Shift indicator may come out of adjustment. Cause: Adjuster did not "collapse" on indicator tape during production, thus creating a low ratcheting effort. Correction: Replace console trim plate with updated part. Refer to "Parts Information" for updated part number. Refer to Section 8C for replacement procedure. Parts Information: 22575236 Trim plate assembly - with power windows 22575237 Trim plate assembly - without power windows Parts are currently available from GMSPO. Warranty Information: Labor Operation Number: K5100 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Component Information > Technical Service Bulletins > Differential Pinion Shaft Lock Screw - Service Differential Assembly: Technical Service Bulletins Differential Pinion Shaft Lock Screw - Service Number: 93-77-4B Section: 4B Date: JAN. 1993 Corporate Bulletin No.: 264207 ASE No.: A3 Subject: DIFFERENTIAL PINION SHAFT LOCKING SCREW Model and Year: 1984-93 CAPRICE AND CAMARO 1984-93 ALL LIGHT DUTY TRUCKS Anytime a differential pinion shaft locking screw is removed (Figure 1), it is important to coat the screw threads with Loctite 242 (GM Part number 12345382), or equivalent, before reinstalling. These screws are coated with an adhesive which helps to prevent the screw from loosening in the case. When this screw is removed, the adhesive is also removed. If a new locking screw is necessary, they are available through GMSPO and are coated with the correct adhesive. Torque the locking screw to the following specifications: 7-1/2", 7-5/8" and 8-1/2" 36 N-m (27 lbs.ft.) 9-1/2" 50 N-m (37 lbs.ft.) PARTS INFORMATION: If a new differential pinion shaft locking screw is required, order the following: Application Part Number 7-1/2", 7-5/8" and 8-1/2" 14056196 9-1/2" 12337979 Goodwrench 242 Threadlooker 12345382 Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Description and Operation Constant Velocity Joint: Description and Operation Fig. 1 Front Wheel Drive Components And Axle Shaft Removal Fig. 2 Front Wheel Drive Components And Axle Shaft Installation. (Typical) The front wheel drive system, Figs. 1, and 2, consists of left and righthand output shafts and drive axles. Each drive axle consists of an axle shaft, with a ball type constant velocity joint at the outboard end and a tri-pot joint at the inboard end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Description and Operation > Page 3272 Fig. 3 Exploded View Of Drive Axle With Tri-pot Inboard Joint. Except Geo Models & LeMans Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Description and Operation > Page 3273 Fig. 4 Exploded View Of Cross-groove Design Drive Axle. Models w/Manual Transmission Except Geo Models & LeMans On all except Geo models and LeMans, a ball type constant velocity joint is used at the outboard end, while a tri-pot type joint is used at the inboard end, Fig. 3. Snap rings are used to lock the male splines of the axle shafts into the transaxle gears, except for the left side inboard joint used with the automatic transaxles. The left side inboard joint used on automatic transaxle models utilizes a female spline which installs over a transaxle stub shaft. On some manual transmissions, a constant velocity joint is used on the inboard end of the drive axle, Fig. 4. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Description and Operation > Page 3274 Constant Velocity Joint: Testing and Inspection CLICKING NOISE IN TURNS Worn or damaged outboard joint. CLUNK WHEN ACCELERATING FROM COAST TO DRIVE Worn or damaged constant velocity joint. SHUDDER OR VIBRATION DURING ACCELERATION 1. Excessive C.V. joint angle. 2. Incorrect toe in or out. 3. Incorrect trim height. 4. Worn or damaged inboard or outboard C.V. joints. 5. Sticking tri-pot joint spider assembly. VIBRATION AT HIGHWAY SPEEDS 1. Out-of-balance front tires or wheels. 2. Out-of-round front tires. 3. Worn C.V. joint. 4. Binding or tight C.V. joint. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replace Constant Velocity Joint: Service and Repair Deflector Ring Replace Fig. 28 Deflector Ring Removal & Installation. Except Geo Models & LeMans For removal and installation procedures, refer to Fig. 28. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replace > Page 3277 Constant Velocity Joint: Service and Repair Inner Constant Velocity Joint & Seal Fig. 27 Cross Groove Inner Joint Seal Removal And Installation. Models w/Cross Groove Inner Joint For removal and installation procedures refer to Fig. 27. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replace > Page 3278 Constant Velocity Joint: Service and Repair Outer Constant Velocity Joint & Seal Fig. 23 Outer Constant Velocity Joint Seal Removal & Installation Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Deflector Ring Replace > Page 3279 Fig. 24 Outer Constant Velocity Joint Disassembly & Assembly For removal and installation procedures refer to Figs. 23 and 24. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair Constant Velocity Joint Boot: Service and Repair Fig. 25 Inner Tri-pot Seal Removal & Installation. Models Less Bearing Blocks Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Page 3283 Fig. 26 Inner Tri-pot Seal Removal & Installation (Part 1 Of 2). Models w/Bearing Blocks Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Page 3284 Fig. 26 Inner Tri-pot Seal Removal & Installation (Part 2 Of 2). Models w/Bearing Blocks For removal and installation procedures, refer to Figs. 25 and 26. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing Removal and Installation Wheel Bearing: Service and Repair Front Wheel Bearing Removal and Installation FRONT WHEEL BEARINGS AND/OR HUB Fig. 2 Modified Outer Seal Protector Fig. 3 Removing And Installing Shaft Nut REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly, then install modified outer seal protector No. J 34754 or equivalent, Fig. 2. 3. Insert a drift punch through the rotor, Fig. 3, then remove axle shaft nut and washer. 4. On 1989-90 models, using a plastic or rubber mallet, strike end of axle shaft to disengage axle from hub and bearing. Shaft nut can be partially installed to protect threads. 5. On 1991-92 models, remove ball joint, then using tool No. J 28733-A or equivalent, disengage axle from hub and bearing assembly. 6. On all models, move axle shaft inward, then remove caliper attaching bolts and support caliper. 7. Remove brake rotor, then hub and bearing assembly attaching bolts. 8. Remove hub and bearing assembly. 9. Reverse to install. Torque attaching bolts to specifications. INSTALLATION 1. Install hub and bearing assembly, torque attaching bolts to specification. 2. Install hub and bearing seal, then the brake rotor. 3. Install caliper, torque attaching bolts to specification. 4. Move axle shaft outward, then insert drift punch through rotor, Fig. 3. 5. Install washer and new shaft nut, torque shaft nut to specification. 6. On 1991-92 models, install ball joint. 7. On all models, remove drift punch and seal protector. 8. Install tire and wheel assembly, then lower vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing Removal and Installation > Page 3289 Wheel Bearing: Service and Repair Rear Suspension REAR HUB AND/OR BEARINGS 1. Raise and support vehicle, then remove wheel and tire assembly and brake drum. Do not hammer brake drum since damage to bearing may result. 2. Remove four hub/bearing assembly to rear axle attaching bolts, then the hub/bearing assembly from axle. The upper rear hub attaching bolt may not clear brake shoe when removing hub and bearing assembly. Partially remove hub and bearing assembly prior to removing this bolt. 3. Reverse procedure to install. Torque hub attaching bolts to specification. Use care not to drop hub/bearing assembly since damage to bearing may result. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut Torque 183 - 192 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Component Information > Specifications Tightening Specifications Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Flywheel To Torque Converter ............................. ............................................................................................................................................................. 46 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > Customer Interest: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned A/T Shift Indicator Module: Customer Interest A/T - Shift Indicator Misaligned Number: 91-458-7A Section: 7A Date: DEC. 1991 Corporate Bulletin No.: 138305 ASE No.: A2 Subject: SHIFT INDICATOR MISALIGNED Model and Year: 1991 CAVALIER WITH AUTOMATIC TRANSMISSION Condition: Shift indicator may come out of adjustment. Cause: Adjuster did not "collapse" on indicator tape during production, thus creating a low ratcheting effort. Correction: Replace console trim plate with updated part. Refer to "Parts Information" for updated part number. Refer to Section 8C for replacement procedure. Parts Information: 22575236 Trim plate assembly - with power windows 22575237 Trim plate assembly - without power windows Parts are currently available from GMSPO. Warranty Information: Labor Operation Number: K5100 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned A/T Shift Indicator Module: All Technical Service Bulletins A/T - Shift Indicator Misaligned Number: 91-458-7A Section: 7A Date: DEC. 1991 Corporate Bulletin No.: 138305 ASE No.: A2 Subject: SHIFT INDICATOR MISALIGNED Model and Year: 1991 CAVALIER WITH AUTOMATIC TRANSMISSION Condition: Shift indicator may come out of adjustment. Cause: Adjuster did not "collapse" on indicator tape during production, thus creating a low ratcheting effort. Correction: Replace console trim plate with updated part. Refer to "Parts Information" for updated part number. Refer to Section 8C for replacement procedure. Parts Information: 22575236 Trim plate assembly - with power windows 22575237 Trim plate assembly - without power windows Parts are currently available from GMSPO. Warranty Information: Labor Operation Number: K5100 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for A/T Shift Indicator Module: > 9313310 > Mar > 93 > Door Locks - Binding or Sticking or Key Hard to Insert Door Lock Cylinder: All Technical Service Bulletins Door Locks - Binding or Sticking or Key Hard to Insert Number: 93-133-10 Section: 10 Date: MARCH 1993 Corporate Bulletin No.: 1341070R ASE No.: B1 Subject: DOOR LOCK CYLINDERS (RECOMMENDED LUBRICATION) Model and Year: ALL 1993 AND PREVIOUS MODEL CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN 92-41-10, DATED NOV. 1991. THE 1993 MODEL YEAR HAS BEEN ADDED AS WELL AS A NOTE. PLEASE DISCARD ALL COPIES OF 92-41-10. Customer comments of binding/sticking door lock cylinders, or keys that are hard to insert or extract may be corrected in many cases by applying the proper lubrication. The recommended materials for lubricating these components are (in order of preference): - GM # 12345120 Multi purpose lubricant (9 oz. spray) or # 12345121 (12 oz.). - 5 W 30 Motor Oil - GM # 1052276 or 1052277 spray type Silicone (4.5 oz. or 12 oz. cans). Penetrating oil type lubricants (such as GM # 1052949 or 1052950, WD-40 lubricants) ARE NOT RECOMMENDED because they wash out the original lubrication and eventually evaporate, leaving little or no lubricating material. However, if these type materials are used to "unfreeze" or loosen lock cylinder components, refer to steps 2 through 4 listed below for the proper methods of lubricating. NOTE: DO NOT REPLACE THE DOOR LOCK CYLINDERS UNTIL AFTER THE LUBRICATING MATERIALS HAVE BEEN USED AND THE CYLINDER REMAINS FROZEN/BOUND. If door lock cylinders require replacement for any reason, apply a coating of GM # 12345120 Multi purpose Lubricant to the inside of the lock case and the cylinder keyway prior to assembling and installing the cylinder. Parts are currently available from GMSPO. Frozen cylinders due to cold weather may be repaired using the following procedure: 1. Apply heat to the cylinder area with a heat gun while being careful not to damage the painted surfaces. 2. Hold the shutter door open with a paper clip (or similar item) and force air into the cylinder using compressed air and a blow gun attachment. 3. While holding the shutter door open, inject a small amount of lubricant (see above recommendations) into the cylinder. 4. Work the key into the cylinder several times and wipe any excess lubrication residue from the key. Use applicable Labor Time Number and Time allowance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Specifications > HM-282 and 5TM40 Bell Housing: Specifications HM-282 and 5TM40 Clutch Housing To Gear Housing ........................................................................................................ .................................................................. 15 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Specifications > HM-282 and 5TM40 > Page 3331 Bell Housing: Specifications GM-Isuzu 5 Speed Manual Transaxle Transaxle Case To Clutch Housing Bolts ......................................................................................................................................................... 22-33 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Specifications Case: Specifications Control Box To Case Bolts .................................................................................................................. ............................................................. 11-16 ft. lbs. Transaxle Case To Clutch Housing Bolts ......................................................................................................................................................... 22-33 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Ring Gear, M/T > Component Information > Specifications > HM-282 and 5TM40 Ring Gear: Specifications HM-282 and 5TM40 Differential Gear .................................................................................................................................. .................................................................. 61 ft. lbs. Differential Pin ..................................................................................................................................... .................................................................... 7 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Ring Gear, M/T > Component Information > Specifications > HM-282 and 5TM40 > Page 3340 Ring Gear: Specifications GM-Isuzu 5 Speed Manual Transaxle Ring Gear Bolts ................................................................................................................................... ............................................................. 73-79 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component Information > Specifications Drain Plug: Specifications Fluid Drain Plug ................................................................................................................................... .................................................................. 18 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fill Plug, M/T > Component Information > Specifications Fill Plug: Specifications Oil Level Check/Fill Plug ...................................................................................................................... ................................................................. 18 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications VIN G, Oil Capacity VIN G, Oil Capacity Isuzu 5 Speed 5.4 pt (US) Muncie 5 Speed 5 pt (US) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 3351 Fluid - M/T: Fluid Type Specifications HM-282 and 5TM40 Lubricant Type ............................................................................................................................................ Synchromesh Trans Fluid (Part No. 12345349) GM-Isuzu 5 Speed Manual Transaxle Lubricant Type ............................................................................................................................................ Synchromesh Trans Fluid (Part No. 12345349) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Specifications > GM-Isuzu 5 Speed Manual Transaxle Input Shaft: Specifications GM-Isuzu 5 Speed Manual Transaxle Input Shaft Retaining Nuts ................................................................................................................... ........................................................... 87-101 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Specifications > GM-Isuzu 5 Speed Manual Transaxle > Page 3356 Input Shaft: Specifications HM-282 and 5TM40 Input Shaft Bearing Support ................................................................................................................ ................................................................... 50 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Specifications > HM-282 and 5TM40 Output Shaft: Specifications HM-282 and 5TM40 Output Bearing Race ........................................................................................................................... ................................................................... 15 ft. lbs. Output Shaft Bearing Support ............................................................................................................. ................................................................... 50 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Specifications > HM-282 and 5TM40 > Page 3361 Output Shaft: Specifications GM-Isuzu 5 Speed Manual Transaxle Output Shaft Retaining Nuts ................................................................................................................ ........................................................... 87-101 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Gear Shaft > Component Information > Specifications Reverse Gear Shaft: Specifications Reverse Idler Shaft Bolts ..................................................................................................................... ............................................................. 22-33 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Idler Gear > Component Information > Specifications Reverse Idler Gear: Specifications Reverse Idler Gear Bracket ................................................................................................................. ................................................................... 15 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications Shifter M/T: Specifications Transaxle Shift Lever To Cable Stud 18 ft.lb Shift Control Box To Transaxle (lsuzu) 13 ft.lb Shift Control To Floor 18 ft.lb Shift Retainer To Transaxle Case (lsuzu) 18 ft.lb Shift Shaft Lever Nut 61 ft.lb Transaxle Shift Cable Bracket To Cables 90 in.lb Shift Cable Grommet To Shroud 18 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments Shift Cable: Adjustments Fig. 4 Isuzu Five Speed Manual Transaxle Shift Cable Adjustment Fig. 5 Muncie Five Speed Manual Transaxle Shift Cable Assembly ISUZU Refer to Fig. 4, for exploded view of shifter cables. MUNCIE Refer to Fig. 5 for exploded view of shifter cables. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shifter Detent Spring > Component Information > Specifications Shifter Detent Spring: Specifications Detent Spring Retaining Bolts ............................................................................................................. ............................................................. 15-21 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Rail, M/T > Component Information > Specifications Shift Rail: Specifications Interlock Plate ...................................................................................................................................... .................................................................. 15 ft. lbs. Reverse Shift Rail Guide ..................................................................................................................... ................................................................... 15 ft. lbs. Shift Rail Detent Holder ....................................................................................................................... .................................................................... 7 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Speedometer Gear, M/T > Component Information > Specifications Speedometer Gear, M/T: Specifications Speedometer/VSS Housing To Transaxle 84 in.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 91448A7A > Jan > 92 > Transaxle Mount - Chirps Transmission Mount: Customer Interest Transaxle Mount - Chirps REVISED Number: 91-448A-7A Section: 7A Date: JAN 1992 Corporate Bulletin No.: 137108 ASE No.: A2, A3 Subject: TRANSAXLE MOUNT CHIRPS Model and Year: 1990-91 CAVALIER, CORSICA BERETTA WITH 2.2L AND 3.1L ENGINES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-448-7A. DATED NOV. 1991. THE 1990-91 2.2L MR7 MANUAL TRANSMISSION HAS BEEN ADDED. ALL COPIES OF 91-448-7A SHOULD BE DISCARDED. Condition: Chirping noise in engine compartment. Cause: Transaxle mount bumper rubs against mount. Correction: Replace transaxle mount bumper with new bumper. Refer to "Parts Information" for vehicle application and updated part number. IMPORTANT: Before transaxle mount bumper is replaced, be sure the bumper is the source of the noise. Coat the bumper with a silicone base grease and test drive vehicle. If noise is no longer evident, replace the bumper. 1. Remove transaxle mount from the vehicle. Refer to appropriate Service Manual and Section for procedure. 2. Place the mount in a vise. Refer to Figure 1. 3. Remove bumper retaining nuts (if not removed during transaxle mount removal). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 91448A7A > Jan > 92 > Transaxle Mount - Chirps > Page 3392 4. Remove bumper. Lift up on the inner mount assembly until the bumper can be removed. Refer to Figure 2. 5. Install new bumper by lifting up on inner mount assembly. 6. Install bumper retaining nuts. 7. Remove mount from vise. 8. Install transaxle mount in the vehicle. Parts Information: Model VIN Car Bumper Year Break Line Engine Transaxle Part Number 1990-91 M7242459 J 2.2L MR7 - Manual 22575852 1990-91 M7242459 J 2.2L 3T40 - Auto 22575853 1990-91 M7242459 J 3.1L MD9 - Auto 22575854 1990-91 M7242459 J 3.1L MG2 - Manual 22575855 1990-91 MY192128 L 2.2L MD9 - Auto 22575853 ME062328 1990-91 MY207010 L ALL MR3 - Manual 22577700 ME063635 Model VIN Car Bumper Year Break Line Engine Transaxle Part Number 1990-91 MY192201 L 3.1L MD9 - Auto 22577701 ME061493 1990-91 MY202773 L 3.1L MG2 - Manual 22577699 ME064089 Parts are currently available from GMSPO. Labor Operation Number: T1790 Labor Time: .8 Hour for 4 cylinder engines with Automatic or Manual Transmission 1.0 Hour for 6 cylinder engines with Automatic or Manual Transmission Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 91448A7A > Jan > 92 > Transaxle Mount - Chirps > Page 3393 Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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: > 91448A7A > Jan > 92 > Transaxle Mount - Chirps Transmission Mount: All Technical Service Bulletins Transaxle Mount - Chirps REVISED Number: 91-448A-7A Section: 7A Date: JAN 1992 Corporate Bulletin No.: 137108 ASE No.: A2, A3 Subject: TRANSAXLE MOUNT CHIRPS Model and Year: 1990-91 CAVALIER, CORSICA BERETTA WITH 2.2L AND 3.1L ENGINES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-448-7A. DATED NOV. 1991. THE 1990-91 2.2L MR7 MANUAL TRANSMISSION HAS BEEN ADDED. ALL COPIES OF 91-448-7A SHOULD BE DISCARDED. Condition: Chirping noise in engine compartment. Cause: Transaxle mount bumper rubs against mount. Correction: Replace transaxle mount bumper with new bumper. Refer to "Parts Information" for vehicle application and updated part number. IMPORTANT: Before transaxle mount bumper is replaced, be sure the bumper is the source of the noise. Coat the bumper with a silicone base grease and test drive vehicle. If noise is no longer evident, replace the bumper. 1. Remove transaxle mount from the vehicle. Refer to appropriate Service Manual and Section for procedure. 2. Place the mount in a vise. Refer to Figure 1. 3. Remove bumper retaining nuts (if not removed during transaxle mount removal). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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: > 91448A7A > Jan > 92 > Transaxle Mount - Chirps > Page 3399 4. Remove bumper. Lift up on the inner mount assembly until the bumper can be removed. Refer to Figure 2. 5. Install new bumper by lifting up on inner mount assembly. 6. Install bumper retaining nuts. 7. Remove mount from vise. 8. Install transaxle mount in the vehicle. Parts Information: Model VIN Car Bumper Year Break Line Engine Transaxle Part Number 1990-91 M7242459 J 2.2L MR7 - Manual 22575852 1990-91 M7242459 J 2.2L 3T40 - Auto 22575853 1990-91 M7242459 J 3.1L MD9 - Auto 22575854 1990-91 M7242459 J 3.1L MG2 - Manual 22575855 1990-91 MY192128 L 2.2L MD9 - Auto 22575853 ME062328 1990-91 MY207010 L ALL MR3 - Manual 22577700 ME063635 Model VIN Car Bumper Year Break Line Engine Transaxle Part Number 1990-91 MY192201 L 3.1L MD9 - Auto 22577701 ME061493 1990-91 MY202773 L 3.1L MG2 - Manual 22577699 ME064089 Parts are currently available from GMSPO. Labor Operation Number: T1790 Labor Time: .8 Hour for 4 cylinder engines with Automatic or Manual Transmission 1.0 Hour for 6 cylinder engines with Automatic or Manual Transmission Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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: > 91448A7A > Jan > 92 > Transaxle Mount - Chirps > Page 3400 Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Page 3401 Transmission Mount: Specifications Rear Mount Bracket To Transaxle 40 ft.lb Rear Transaxle Mount To Body 23 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Specifications Fluid Pressure Sensor/Switch: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Pressure Switch ................................................................................................................................... ................................................................................. 8 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations Transmission Position Switch/Sensor: Locations Rear Of 3.1L Rear Of Engine, Top LH Side Of Transaxle Applicable to: 1L/V6-192 Engine. Cavalier w/Automatic Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 3410 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch & Connector The PARK/NEUTRAL switch indicates to the computer when the transmission is in park or neutral. This information is used by the computer for ignition timing, Idle Air Control (IAC), and Transmission Torque Converter Clutch (TCC) operation. DO NOT drive the vehicle with the PARK/NEUTRAL switch disconnected, since idle quality may be affected. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 3411 Transmission Position Switch/Sensor: Testing and Inspection Chart C-1A Wiring Diagram For P/N Switch CIRCUIT DESCRIPTION: The PARK/NEUTRAL switch contacts are closed to ground in park or neutral and open in drive ranges. The ECM supplies ignition voltage through a current limiting resistor to circuit 434, and senses a closed switch when the voltage on circuit 434 drops to less than one volt. The ECM uses the P/N signal as one of the inputs to control idle air and vehicle speed sensor diagnostics. TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 3412 1. Checks for a closed switch to ground in the PARK position. Different makes of "Scan" tools will read PARK/NEUTRAL differently. Refer to operators manual for type of display used for a specific tool. 2. Checks for an open switch in drive range. 3. Be sure the "Scan" tool indicates drive even while wiggling the shifter to test for an intermittent or misadjusted switch in drive. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 3413 Transmission Position Switch/Sensor: Adjustments 1. Place transaxle shift lever in NEUTRAL. 2. Loosen switch attaching screws. 3. Rotate switch on shaft assembly to align service adjustment hole with carrier tang hole. a. Insert 2.34 mm (3/32 inch) maximum diameter gauge pin to a depth of 15.0 mm (5/8 inch). 4. Tighten attaching screws. See SPECIFICATIONS/MECHANICAL for torque values. 5. Remove the gauge pin. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 3414 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Start and Backup Lamp Switch 1. Remove negative battery cable, shift linkage, electrical connector, mounting bolts, and switch assembly. 2. Replacement using old or new switch. a. Place shift shaft in NEUTRAL. b. Align flats of shift shaft with switch. c. Old Switch only - Install mounting bolts-to-case, loosely. Insert gauge pin in service adjustment hole, and rotate switch until pin drops into a depth of 9.0 mm (9/64") and tighten bolts (see SPECIFICATIONS/MECHANICAL for torque values). d. New Switch only - Install mounting bolts and tighten. If bolt holes do not align with mounting boss on transaxle, verify that the shift shaft is in NEUTRAL; DO NOT rotate the switch. The switch is pinned in the NEUTRAL position. NOTE: If the switch has been rotated and the pin is broken, the switch can be adjusted using the old switch procedure and ADJUSTMENT PROCEDURES. 3. See ADJUSTMENT PROCEDURES for PARK/NEUTRAL switch adjustment. 4. After the switch is installed, verify that the engine will start only in PARK (A/T) or NEUTRAL (M/T). If the engine starts in any other position, readjust the switch using old switch procedure and ADJUSTMENT PROCEDURES. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Electronic Speed Sensor Retainer ...................................................................................................... ...................................................................... 7 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Specifications Shift Solenoid: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Solenoid To Valve Body ....................................... .............................................................................................................................................................. .8 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 Cover, Auxiliary Valve Body And Pump 3T40 (125C) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 3427 Torque Converter Clutch Solenoid: Description and Operation The purpose of the Transmission Converter Clutch (TCC) feature is to eliminate the power loss of the torque converter stage when the vehicle is in a cruise mode. The TCC System uses a solenoid operated valve to couple the engine flywheel to the output shaft of the transmission through the torque converter. Lockup reduces slippage in the converter increasing fuel economy. For the converter clutch to apply, two conditions must be met: 1. Internal transmission fluid pressure must be correct. 2. The ECM must complete a ground circuit to energize the TCC solenoid which moves a check ball in the fluid line. This allows the converter clutch to apply, when hydraulic pressure is correct. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Service and Repair > Torque Converter Clutch (TCC) Solenoid Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch (TCC) Solenoid TORQUE CONVERTER CLUTCH (TCC) SOLENOID & SWITCHES 3T40 (125C) Auxiliary Valve Body, Valve Body And Oil Pump Assembly Torque Converter Clutch Solenoid & Switches REMOVE OR DISCONNECT 1. Negative battery cable. 2. Raise vehicle and suitably support. 3. Drain fluid. 4. Left front tire and wheel assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 3430 5. Valve body cover. Refer to "Valve Body Cover". 6. Wiring harness from case electrical connector and leads from 3rd clutch pressure switch. 7. Torque converter clutch bolt to auxiliary valve body. 8. 3rd clutch pressure switch. 9. Second clutch switch, if applicable. INSTALL OR CONNECT 1. Second clutch switch, if applicable. TIGHTEN ^ Switch to 11 Nm (8 lb. ft.). 2. 3rd clutch pressure switch. TIGHTEN ^ Switch to 11 Nm (8 lb. ft.). 3. Torque converter clutch bolt to auxiliary valve body. Install new O-ring. TIGHTEN ^ Bolt to 11 Nm (8 lb. ft.). 4. Wire harness to case and switches. 5. Valve body cover with a new gasket. Refer to "Valve Body Cover". 6. Lower vehicle. 7. Negative battery cable. ADJUST ^ T.V. cable. ^ Fluid level. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 3431 Torque Converter Clutch Solenoid: Service and Repair Valve Body Cover VALVE BODY COVER 3T40 (125C) Side Cover And Control Valve View REMOVE OR DISCONNECT 1. Raise vehicle and suitably support. 2. Drain oil. 3. Left front tire and wheel assembly. 4. Left splash shield. 5. Valve body cover to transaxle bolts. INSPECT ^ Bolts INSTALL OR CONNECT 1. Valve body cover with a new gasket and bolts. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 3432 Valve Body Cover NOTE: It is necessary to use GM thread locker (P/N 12345382) or equivalent non-locking sealant to reduce the potential for fluid leaks on the indicated bolts. 2. Left splash shield. 3. Left front tire and wheel assembly. 4. Lower vehicle. ADJUST ^ Oil level. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > Customer Interest: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned A/T Shift Indicator Module: Customer Interest A/T - Shift Indicator Misaligned Number: 91-458-7A Section: 7A Date: DEC. 1991 Corporate Bulletin No.: 138305 ASE No.: A2 Subject: SHIFT INDICATOR MISALIGNED Model and Year: 1991 CAVALIER WITH AUTOMATIC TRANSMISSION Condition: Shift indicator may come out of adjustment. Cause: Adjuster did not "collapse" on indicator tape during production, thus creating a low ratcheting effort. Correction: Replace console trim plate with updated part. Refer to "Parts Information" for updated part number. Refer to Section 8C for replacement procedure. Parts Information: 22575236 Trim plate assembly - with power windows 22575237 Trim plate assembly - without power windows Parts are currently available from GMSPO. Warranty Information: Labor Operation Number: K5100 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned A/T Shift Indicator Module: All Technical Service Bulletins A/T - Shift Indicator Misaligned Number: 91-458-7A Section: 7A Date: DEC. 1991 Corporate Bulletin No.: 138305 ASE No.: A2 Subject: SHIFT INDICATOR MISALIGNED Model and Year: 1991 CAVALIER WITH AUTOMATIC TRANSMISSION Condition: Shift indicator may come out of adjustment. Cause: Adjuster did not "collapse" on indicator tape during production, thus creating a low ratcheting effort. Correction: Replace console trim plate with updated part. Refer to "Parts Information" for updated part number. Refer to Section 8C for replacement procedure. Parts Information: 22575236 Trim plate assembly - with power windows 22575237 Trim plate assembly - without power windows Parts are currently available from GMSPO. Warranty Information: Labor Operation Number: K5100 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for A/T Shift Indicator Module: > 914131A > Sep > 91 > Heater - Low Output Air Door Cable: All Technical Service Bulletins Heater - Low Output Number: 91-413-1A Section: 1A Date: SEPT. 1991 Corporate Bulletin No.: 131104 ASE No.: A7 Subject: LOW HEAT DELIVERY RELATED DIAGNOSIS REVISED PROCEDURE Model and Year: 1989-91 CAVALIER On customer comments of low heater output on 1989-91 J cars, before replacing a suspected defective engine cooling thermostat, proper diagnosis of the condition must be performed to avoid the possibility of a repeat repair. Follow "Diagnosis" as shown in Section 1A/1B of the appropriate Service Manual. After completing the diagnosis, use the following as a guide to the next corrective step: ^ If the diagnosis indicates a defective thermostat, refer to Section 6C for replacement. ^ If the diagnosis indicates a defective temperature control cable, refer to Section 1A/1B for replacement. ^ If the diagnosis indicates the temperature control cable is no longer "snapped" into its retainer, refer to "Temperature Control Cable Repair" in the 1991 Service Manual, Sections 1A/1B. ^ If the diagnosis indicates that the temperature control cable is out of adjustment, refer to the following procedure to repair. TEMPERATURE CONTROL CABLE ADJUSTMENT PROCEDURE Condition: 1. "Spring back" off full "hot" temperature control position (or not attaining full "cold" temperature door position). Condition: 2. "Spring back" off full "cold" temperature control position (or not attaining full "hot" temperature door position). Cause: The temperature control cable "clip" needs adjustment. Refer to the illustration for correct gripping of the "clip" during adjustment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for A/T Shift Indicator Module: > 914131A > Sep > 91 > Heater - Low Output > Page 3454 Correction For Number: 1. Grip "clip" at module end of cable while pulling temperature control lever to "hot" position. Correction For Number: 2. Grip "clip" at module end of cable while pushing temperature control lever to "cold" position. NOTICE: FAILURE TO GRIP "CLIP" CORRECTLY WILL DAMAGE ITS ABILITY TO HOLD POSITION ON THE CABLE. THE TEMPERATURE CONTROL CABLE MUST BE REPLACED IF "CLIP" RETENTION FAILS. Verify correct adjustment after repair by observing for no, or very liftle, "spring back" of the temperature control lever and listening for temperature door "slam" when the control lever is moved to full hot and cold positions quickly. Please note your copies of the Service Manuals in Sections 1A and 1B, under "Temperature Control Cable", with these new adjustment instructions. Warranty and Labor Information: Use the appropriate failure code for each occurrence. For thermostat or temperature control cable replacement, use current applicable warranty and labor information. For temperature cable repair at the heater control, use current heater warranty and labor information. For temperature control repair at the HVAC module or cable adjustment: Labor Operation Number: D0400 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for A/T Shift Indicator Module: > 914131A > Sep > 91 > Heater - Low Output > Page 3460 Correction For Number: 1. Grip "clip" at module end of cable while pulling temperature control lever to "hot" position. Correction For Number: 2. Grip "clip" at module end of cable while pushing temperature control lever to "cold" position. NOTICE: FAILURE TO GRIP "CLIP" CORRECTLY WILL DAMAGE ITS ABILITY TO HOLD POSITION ON THE CABLE. THE TEMPERATURE CONTROL CABLE MUST BE REPLACED IF "CLIP" RETENTION FAILS. Verify correct adjustment after repair by observing for no, or very liftle, "spring back" of the temperature control lever and listening for temperature door "slam" when the control lever is moved to full hot and cold positions quickly. Please note your copies of the Service Manuals in Sections 1A and 1B, under "Temperature Control Cable", with these new adjustment instructions. Warranty and Labor Information: Use the appropriate failure code for each occurrence. For thermostat or temperature control cable replacement, use current applicable warranty and labor information. For temperature cable repair at the heater control, use current heater warranty and labor information. For temperature control repair at the HVAC module or cable adjustment: Labor Operation Number: D0400 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Specifications Fluid Pressure Sensor/Switch: Specifications COMPONENT ..................................................................................................................................... ....................................................... Torque/Ft.Lbs Pressure Switch ................................................................................................................................... ................................................................................. 8 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations Transmission Position Switch/Sensor: Locations Rear Of 3.1L Rear Of Engine, Top LH Side Of Transaxle Applicable to: 1L/V6-192 Engine. Cavalier w/Automatic Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 3469 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch & Connector The PARK/NEUTRAL switch indicates to the computer when the transmission is in park or neutral. This information is used by the computer for ignition timing, Idle Air Control (IAC), and Transmission Torque Converter Clutch (TCC) operation. DO NOT drive the vehicle with the PARK/NEUTRAL switch disconnected, since idle quality may be affected. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 3470 Transmission Position Switch/Sensor: Testing and Inspection Chart C-1A Wiring Diagram For P/N Switch CIRCUIT DESCRIPTION: The PARK/NEUTRAL switch contacts are closed to ground in park or neutral and open in drive ranges. The ECM supplies ignition voltage through a current limiting resistor to circuit 434, and senses a closed switch when the voltage on circuit 434 drops to less than one volt. The ECM uses the P/N signal as one of the inputs to control idle air and vehicle speed sensor diagnostics. TEST DESCRIPTION: The numbers below refer to circled numbers on the diagnostic chart. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 3471 1. Checks for a closed switch to ground in the PARK position. Different makes of "Scan" tools will read PARK/NEUTRAL differently. Refer to operators manual for type of display used for a specific tool. 2. Checks for an open switch in drive range. 3. Be sure the "Scan" tool indicates drive even while wiggling the shifter to test for an intermittent or misadjusted switch in drive. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 3472 Transmission Position Switch/Sensor: Adjustments 1. Place transaxle shift lever in NEUTRAL. 2. Loosen switch attaching screws. 3. Rotate switch on shaft assembly to align service adjustment hole with carrier tang hole. a. Insert 2.34 mm (3/32 inch) maximum diameter gauge pin to a depth of 15.0 mm (5/8 inch). 4. Tighten attaching screws. See SPECIFICATIONS/MECHANICAL for torque values. 5. Remove the gauge pin. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Locations > Page 3473 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Start and Backup Lamp Switch 1. Remove negative battery cable, shift linkage, electrical connector, mounting bolts, and switch assembly. 2. Replacement using old or new switch. a. Place shift shaft in NEUTRAL. b. Align flats of shift shaft with switch. c. Old Switch only - Install mounting bolts-to-case, loosely. Insert gauge pin in service adjustment hole, and rotate switch until pin drops into a depth of 9.0 mm (9/64") and tighten bolts (see SPECIFICATIONS/MECHANICAL for torque values). d. New Switch only - Install mounting bolts and tighten. If bolt holes do not align with mounting boss on transaxle, verify that the shift shaft is in NEUTRAL; DO NOT rotate the switch. The switch is pinned in the NEUTRAL position. NOTE: If the switch has been rotated and the pin is broken, the switch can be adjusted using the old switch procedure and ADJUSTMENT PROCEDURES. 3. See ADJUSTMENT PROCEDURES for PARK/NEUTRAL switch adjustment. 4. After the switch is installed, verify that the engine will start only in PARK (A/T) or NEUTRAL (M/T). If the engine starts in any other position, readjust the switch using old switch procedure and ADJUSTMENT PROCEDURES. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 > Specifications Transmission Speed Sensor: Specifications Electronic Speed Sensor Retainer ...................................................................................................... ...................................................................... 7 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > System Information > Technical Service Bulletins > Anti-Lock Brake - Aftermarket Products Usage Precaution Antilock Brakes / Traction Control Systems: Technical Service Bulletins Anti-Lock Brake Aftermarket Products Usage Precaution Group Ref.: Brakes Bulletin No.: 435001 Date: February, 1994 INFORMATION SUBJECT: AFTERMARKET ANTI-LOCK BRAKE SYSTEM PRODUCTS MODELS: 1994 AND PRIOR PASSENGER CARS AND TRUCKS The brake system is one of the most important features on any passenger vehicle. Several products which tap into the master cylinder and/or brake system and claim to improve brake system performance are being sold in the aftermarket. Some of these products imply performance similar to new vehicle anti-lock brake systems. However, contrary to their claims, add-on systems which deplete fluid from the master cylinder on brake apply may actually increase a vehicle's stopping distance. This may cause the vehicle to fail to comply with Federal Motor Vehicle Safety Standard (FMVSS) 105. If this happens, the facility which altered the vehicle could be liable for rendering the brake system "inoperative". GM would like to remind each dealer of their legal obligation with regard to any actions which might take a vehicle out of compliance with FMVSS, and to stress the need to understand the operation of any aftermarket system offered to your customers. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Hydraulic System Bleeding Brake Bleeding: Service and Repair Hydraulic System Bleeding Manual Bleeding Pressure bleeding is recommended for all non-ABS hydraulic systems. However, if a pressure bleeder is unavailable, use the following procedure. Brake fluid damages painted surfaces. Immediately clean any spilled fluid. 1. Remove vacuum reserve by pumping brakes several times with engine off. 2. Fill master cylinder reservoir with clean brake fluid. Check fluid level often during bleeding procedure; do not let reservoir fall below half full. 3. If necessary, bleed master cylinder as follows: a. Disconnect master cylinder forward brake line connection until fluid flows from reservoir. Reconnect and tighten brake line. b. Instruct an assistant to slowly depress brake pedal one time and hold. c. Crack open front brake line connection again, purging air from cylinder. d. Retighten connection and slowly release brake pedal. e. Wait 15 seconds, then repeat until all air is purged. f. Bleed the rearward (nearest the cowl) brake line connection by repeating steps a through e. 4. Loosen, then slightly retighten bleeder valves at all four wheels. Repair any broken, stripped or frozen valves at this time. 5. Proceed to appropriate wheel first and follow set sequence according to the bleeding sequence. Bleeding Sequence: RR-LF-LR-RF Fig. 20 Bleeding Brakes 6. Place transparent tube over bleeder valve, then allow tube to hang down into transparent container, Fig. 20. Ensure end of tube is submerged in clean brake fluid. 7. Instruct an assistant to slowly depress brake pedal one time and hold. 8. Crack open bleeder valve, purging air from cylinder. Retighten bleeder screw and slowly release pedal. 9. Wait 15 seconds, then repeat steps 7 and 8. Repeat these steps until all air is bled from system. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Hydraulic System Bleeding > Page 3486 Fig. 21 Installing Pressure Bleeder Adapter Fig. 20 Bleeding Brakes Pressure Bleeding, Non-ABS Only 1. Loosen, then slightly retighten bleeder valves at all four wheels. Repair any broken, stripped or frozen valves at this time. 2. Using a diaphragm type pressure bleeder, install suitable bleeder adapter to master cylinder, Fig. 21. 3. Charge bleeder ball to 20-25 psi. 4. Connect pressure bleeder line to adapter. 5. Open line valve on pressure bleeder, then depress bleed-off valve on adapter until a small amount of brake fluid is released. 6. Raise and support vehicle. 7. Proceed to appropriate wheel first and follow set sequence according to Wheel Bleeding Sequence. 8. Place transparent tube over bleeder valve, then allow tube to hang down into transparent container, Fig. 20. Ensure end of tube is submerged in clean brake fluid. 9. Open bleeder valve 1/2 to 3/4 turn and allow fluid to flow into container until all air is purged from line. Wheel Bleeding Sequence Rear wheel drive models except Corvette: if manual bleeding, RR-LR-RF-LF; if pressure bleeding, bleed front brakes together and rear brakes together. Front wheel drive models except Spectrum: RR-LF-LR-RF. 1989 Corvette: RF-RR-LR-LF. Spectrum: LF-RR-RF-LR. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Hydraulic System Bleeding > Page 3487 Flushing Hydraulic System If brake fluid is old, rusty or contaminated, or whenever new parts are installed in hydraulic system, the system must be flushed. Bleed brakes, allowing at least one quart of clean brake fluid to pass through system. Any rubber parts in hydraulic system which were exposed to contaminated fluid must be replaced. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Hydraulic System Bleeding > Page 3488 Brake Bleeding: Service and Repair Master Cylinder Bleeding This procedure can be performed with master cylinder on or off vehicle. CAUTION: Brake fluid will damage painted surfaces. Brake fluid can also damage electrical connections. Shop cloths and clean containers should be used to prevent spillage of brake fluid. 1. Disconnect brake lines at master cylinder, if necessary. 2. Connect suitable lengths of brake lines to master cylinder and immerse other ends of lines in master cylinder reservoirs. 3. Apply master cylinder pushrod or brake pedal with full strokes until air bubbles have disappeared in reservoirs. It may require 20-30 applications to fully eliminate air bubbles. 4. Remove bleeding lines from master cylinder, then install master cylinder on vehicle, if necessary, and connect brake lines. 5. Fill the reservoir. Normal bleeding procedures should be followed after the master cylinder is installed. For additional information see Bench Bleeding. See: Hydraulic System/Brake Master Cylinder/Fundamentals and Basics Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Page 3489 Brake Bleeding: Fundamentals and Basics BENCH BLEEDING Why A master-cylinder will develop little or no pressure if air is trapped in cylinder bore. Normal brake bleeding will not remove air trapped within the master-cylinder. How Clamp the master-cylinder securely in a vice. It is usually best to clamp the side of the vice onto the flat surface that is used to secure the master-cylinder to the brake booster. There are two basic methods for bleeding master-cylinder, one utilizes stroking the master-cylinder to expel air from the cylinder bore while the other utilizes a large syringe to backflush fluid from the outlet ports to the reservoir. Stroking Fill the master-cylinder with clean brake fluid. - The brake line fittings on the master-cylinder should be capped or plugged. NOTE: Special "bench bleeding" plastic fittings are available which allow for recirculating the brake fluid back into the reservoir. - Using a dull object, slowly stroke the master-cylinder piston, air and brake fluid will be expelled from the brake line fittings. Prior to releasing the piston plug or cap the outlet ports. - Repeat this procedure 8-10 times or until no air is emitted from the outlet ports. - When finished, cap the outlet ports and install the master-cylinder. Syringe Fill the syringe (one especially designed for brake bleeding) with clean brake fluid. - Insert the end of the syringe into one of the outlet ports on the master-cylinder. - Slowly compress the syringe and back flush the brake fluid through the master-cylinder. - A combination of air and brake fluid will be emitted from the inlet port in the fluid reservoir. - Repeat this procedure until only brake fluid is emitted into the reservoir. Cap the outlet ports and install the master-cylinder. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Service and Repair Brake Warning Indicator: Service and Repair This lamp will be illuminated when the ignition switch is placed in the ON position. The lamp may be illuminated for as long as 30 seconds as a bulb and system check. If the lamp remains illuminated or comes on while operating the vehicle, a problem in the ANTILOCK brake system is indicated. When lamp is illuminated, place the ignition switch in OFF position, then restart engine. If lamp still remains illuminated, the anti-lock brake system should be serviced. The brake system will remain functional, without the anti-lock function. After servicing the anti-lock system the lamp will automatically reset. On some models it may be necessary to operate vehicle at a speed over 18 mph to reset lamp. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest: > 92455 > Nov > 91 > Brakes (Front) - Caliper Not Sliding Freely, Corrosion Brake Caliper: Customer Interest Brakes (Front) - Caliper Not Sliding Freely, Corrosion Number: 92-45-5 Section: 5 Date: NOV. 1991 Corporate Bulletin No.: 135017 ASE No.: A5 Subject: FRONT DISC BRAKE CALIPER BOLT BORE CORROSION Model and Year: 1990-92 CAVALIER, CORSICA AND BERETTA Condition: Some 1990-92 J/L cars may experience a condition of a caliper not sliding freely or moving on the mounting bolts inward toward the center of the vehicle. FIGURE 1 Cause: This condition is due to corrosion in the caliper mounting bolt area (See Figure 1) caused by contaminates seeping past the mounting bolt rubber bushing. Correction: Inspect the caliper suspension mounting bolts and sleeves for corrosion. Also, inspect the bushings for cuts, nicks and/or excessive wear. If damage to either part is found, replace with new parts. IMPORTANT: Do Not attempt to polish away corrosion from the bolt or sleeve assemblies. Lubricate the bushing bore with silicone grease, contained in Bushing Kit, P/N 18017226 or equivalent and install bolt and sleeve assembly. The bolt and sleeve assembly should slide through the bushing without the use of mechanical assistance. If the force required to slide the bolt and sleeve exceeds hand assembly pressure, remove the bushings and inspect the mounting bores for corrosion. * If bores show signs of corrosion, clean the bores with a one inch wheel cylinder honing brush. IMPORTANT: Replace rubber bushings with new parts contained in service kit, P/N 18017226 whenever they are removed from housing. Parts are currently available from GMSPO. Labor Operation Number: T1781 Labor Time: 1.2 Hours Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92455 > Nov > 91 > Brakes (Front) - Caliper Not Sliding Freely, Corrosion Brake Caliper: All Technical Service Bulletins Brakes (Front) - Caliper Not Sliding Freely, Corrosion Number: 92-45-5 Section: 5 Date: NOV. 1991 Corporate Bulletin No.: 135017 ASE No.: A5 Subject: FRONT DISC BRAKE CALIPER BOLT BORE CORROSION Model and Year: 1990-92 CAVALIER, CORSICA AND BERETTA Condition: Some 1990-92 J/L cars may experience a condition of a caliper not sliding freely or moving on the mounting bolts inward toward the center of the vehicle. FIGURE 1 Cause: This condition is due to corrosion in the caliper mounting bolt area (See Figure 1) caused by contaminates seeping past the mounting bolt rubber bushing. Correction: Inspect the caliper suspension mounting bolts and sleeves for corrosion. Also, inspect the bushings for cuts, nicks and/or excessive wear. If damage to either part is found, replace with new parts. IMPORTANT: Do Not attempt to polish away corrosion from the bolt or sleeve assemblies. Lubricate the bushing bore with silicone grease, contained in Bushing Kit, P/N 18017226 or equivalent and install bolt and sleeve assembly. The bolt and sleeve assembly should slide through the bushing without the use of mechanical assistance. If the force required to slide the bolt and sleeve exceeds hand assembly pressure, remove the bushings and inspect the mounting bores for corrosion. * If bores show signs of corrosion, clean the bores with a one inch wheel cylinder honing brush. IMPORTANT: Replace rubber bushings with new parts contained in service kit, P/N 18017226 whenever they are removed from housing. Parts are currently available from GMSPO. Labor Operation Number: T1781 Labor Time: 1.2 Hours Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 83-81-34 > Mar > 99 > SIR Operating Vehicle with Warning Light On Malfunction Lamp / Indicator: All Technical Service Bulletins SIR - Operating Vehicle with Warning Light On File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-34 Date: March, 1999 INFORMATION Subject: Operating Vehicle with Supplemental Inflatable Restraint (SIR) Warning Light Illuminated Models: 1999 and Prior Passenger Cars and Light Duty Trucks with SDM Controlled Air Bag System The AIR BAG warning light is the key to driver notification of Supplemental Inflatable Restraint (SIR) system malfunctions. When the warning light remains illuminated or continues to flash, one or more of the following conditions may occur if vehicle operation is continued. ^ Non-deployment of the air bags in the event of a crash. ^ Deployment of the air bags without a crash. ^ Deployment of the air bags in crashes less severe than intended. If an AIR BAG warning light is illuminated or flashing, you should advise the customer of these possibilities and that the vehicle should be serviced right away. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Page 3517 Brake Caliper: Specifications Caliper Mounting Bolts 38 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Page 3518 Brake Caliper: Description and Operation Disc Brake Caliper Assembly This caliper has a single bore and is mounted to the support bracket with two mounting bolts. Hydraulic pressure, created by applying force to the brake pedal, is converted by the caliper into friction. The hydraulic pressure is applied equally against the piston and the bottom of the caliper bore moving the piston outward, resulting in a clamping action on the brake rotor. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Page 3519 Brake Caliper: Testing and Inspection Honing caliper piston bore Should it become necessary to remove the caliper for installation of new parts, clean all parts in alcohol, wipe dry using lint free cloths, using an air hose to blow out drilled passages and bores. Check dust boots for punctures or tears. If punctures or tears are evident, new boots should be installed upon reassembly. Inspect piston bores in both housings for scoring or pitting. Bores that show light scratches or corrosion can usually be cleaned with crocus cloth. However, bores that have deep scratches or scoring may be honed, provided the diameter of the bore is not increased more than .002 inches. If the bore does not clean up within this specification, a new caliper housing should be installed (black stains on the bore walls are caused by piston seals and will do no harm). When using a hone be sure to install the hone baffle before honing bore. The baffle is used to protect the hone stones from damage. Use extreme care in cleaning the caliper after honing. Remove all dust and grit by flushing the caliper with alcohol. Wipe dry with clean lint free cloth and then clean a second time in the same manner. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal Brake Caliper: Service and Repair Caliper Removal For additional information see Removal Notes. See: Fundamentals and Basics Compressing Piston Compressing Caliper Piston NOTE: If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. CAUTION: Brake fluid will damage painted surfaces. Brake fluid can also damage electrical connections. Shop cloths and clean containers should be used to prevent spillage of brake fluid. 1. Remove approximately 2/3 of brake fluid from master cylinder. 2. Raise vehicle and support on jack stands. 3. Mark relationship of wheel to hub and bearing assembly. 4. Remove front wheels. 5. Reinstall two wheel nuts to retain rotor to hub and bearing assembly. 6. Position suitable pliers over outboard pad and housing as shown in image and squeeze pliers to compress caliper piston. This will provide clearance between linings and rotor. The piston can also be bottomed in the bore with a large C-clamp. Refer to image. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3522 Caliper Mounting Fig. 5 Removing Caliper Mounting Bolts Suspending Caliper NOTE: If removing caliper assembly only to access other brake parts do not remove brake inlet fitting as indicated in step 7. If the inlet fitting (11) is disconnected, caliper must be bled when reinstalling. 7. Remove bolt attaching inlet fitting (11) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3523 8. Plug openings in caliper housing (10) and inlet fitting (11) to prevent fluid loss and contamination. CAUTION: Do not crimp brake hose, as this may damage internal structure. 9. Remove caliper mounting bolts and sleeves (1). 10. Remove caliper (10) from rotor and caliper mounting bracket (12). ^ If the caliper assembly is not being removed from the vehicle for unit repair, suspend the caliper with a wire hook from the strut. Refer to image. 11, Inspect Caliper ^ Mounting bolts and sleeves (1) for corrosion. ^ Bushings (2) for cuts or nicks. ^ If damage to either part is found, replace with new parts when installing caliper. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3524 Brake Caliper: Service and Repair Caliper Overhaul 1. Remove caliper completely from vehicle 2. Clean outside of caliper, then drain brake fluid from caliper. WARNING: Do not place fingers in front of piston for any reason when applying compressed air. This could result in serious personal injury. Fig. 6 Applying Compressed Air To Caliper Line Port Disc Brake Caliper Assembly 3. Use clean shop towels to pad interior of caliper assembly, then remove piston by directing compressed air into caliper brake hose inlet hole. Use just enough air pressure to ease piston out of bore. 4. Remove piston (9) from the caliper. INSPECT ^ Piston for scoring, nicks, corrosion and worn or damaged chrome plating. Replace piston if any of these conditions are found. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3525 Removing Boot 5. Remove boot (6) from caliper housing bore. Be careful not to scratch housing bore. CAUTION: Do not use a metal tool to remove piston seal. This may damage caliper bore or seal groove. Caliper Assembly 6. Remove piston seal (10) from seal groove in caliper housing (12) bore with a small wood or plastic tool. INSPECT ^ Caliper housing bore and seal groove for scoring, nicks, corrosion and wear. 7. Use crocus cloth to polish out light corrosion. Replace caliper housing if corrosion in and around seal groove will not clean up with crocus cloth. 8. Remove bleeder valve (11) from caliper. 9. Clean all parts in clean, denatured alcohol. Dry with unlubricated compressed air. 10. Blow out all passages in caliper housing and bleeder valve. ASSEMBLY 1. Install bleeder valve into caliper. 2. Tighten bleeder valve to 13 Nm (10 lbs. ft.) 3. Lubricate all rubber parts with clean brake fluid prior to installation. 4. Install piston seal (10) into caliper seal groove. Be sure seal is not twisted. Installing Boot Onto Piston 5. Install boot onto piston. 6. Install piston and boot into bore of caliper and push to bottom of bore. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3526 Seating Boot Into Caliper Housing 7. Seat boot in caliper housing counterbore using J 29077-A or equivalent. 8. Install caliper. Refer to Caliper Installation. 1. Remove caliper completely from vehicle 2. Clean outside of caliper, then drain brake fluid from caliper. WARNING: Do not place fingers in front of piston for any reason when applying compressed air. This could result in serious personal injury. 3. Remove piston (5) from the caliper. 4. Use clean shop towels to pad interior of caliper assembly (10,) then remove piston by directing compressed air into caliper brake hose inlet hole. Use just enough air pressure to ease piston out of bore. INSPECT ^ Piston (5) for scoring, nicks, corrosion and worn or damaged chrome plating. Replace piston (5) if any of these conditions are found. 5. Remove boot (6) from caliper housing bore. Be careful not to scratch housing bore. CAUTION: Do not use a metal tool to remove piston seal in step 6. This may damage caliper bore or seal groove. 6. Remove piston seal (4) from seal groove (16) in caliper housing (10) bore with a small wood or plastic tool. INSPECT ^ Caliper housing (10) bore and seal groove (16) for scoring, nicks, corrosion and wear. 7. Use crocus cloth to polish out light corrosion. Replace caliper housing if corrosion in and around seal groove will not clean up with crocus cloth. 8. Remove bleeder valve (3) from caliper (1). 9. Clean all parts in clean, denatured alcohol. Dry with unlubricated compressed air. 10. Blow out all passages in caliper housing (10) and bleeder valve (3). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3527 Seating Boot Into Caliper Housing Caliper Assembly ASSEMBLY 1. Install bleeder valve (3) into caliper (10). 2. Tighten bleeder valve (3) to 13 Nm (115 lbs. in.) 3. Lubricate all rubber parts with clean brake fluid prior to installation. 4. Install piston seal (4) into caliper seal groove (16). Be sure seal is not twisted. 5. Install boot (6) onto piston (5). 6. Install piston (5) and boot (6) into bore of caliper and push to bottom of bore. 7. Seat boot (6) in caliper housing (10) counterbore using J 29077-A or equivalent. 8. Install bushings (2). 9. Lubricate beveled end of bushing with silicone grease, GM Part Number 1052863 or equivalent. 10. Pinch bushing and install bevel end first through housing mounting bore. 11. Install caliper. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3528 Brake Caliper: Service and Repair Caliper Installation For additional information see Installation Notes. See: Fundamentals and Basics Inboard Shoe And Retaining Spring Disc Brake Caliper Assembly Installing Outboard Shoe And Lining Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3529 1. Install inboard shoe and lining (7) by snapping shoe retaining sprlng (14) into piston (5) inside diameter. Shoe must lay flat against piston. 2. Install outboard shoe and lining (8) with wear sensor (9) at leading edge of shoe. During forward wheel rotation, the back of the shoe must lay flat against caliper. 3. Liberally coat inside diameter of bushings (2) with silicone grease. Caliper To Bracket Clearance 4. Position caliper assembly over disc and align mounting bolt holes (12). If brake hoses were not disconnected during removal, use care not to kink hoses during installation. 5. Install mounting bolts and tighten to 51 Nm (38 lbs. ft.). 6. Check clearance between caliper (10) and stops on the bracket (12). Clearance should be 0.13 to 0.30 mm (0.005 to 0.012 inch). If necessary, remove caliper and file ends of the stops on the bracket (12) to provide proper clearance. 7. Install inlet fitting, if removed and torque to 45 Nm (33 lbs. ft.). 8. Fill master cylinder. Bleed brake system if brake line was disconnected and recheck master cylinder fluid level. 9. Apply a firm force three times to brake pedal to seat linings. Clinching Procedure (Step 1) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3530 Clinching Procedure (Step 2) 10. Pry up on outboard shoe with large flat-blade screwdriver or similar tool between outboard shoe flange and hat section of rotor. Keep tool wedged in place during the following step. 11. Hold moderate force on brake pedal and clinch outboard shoe tabs (13) using procedure shown in image. Outboard shoe should be locked tightly in position. 12. Remove wheel nuts securing rotor to hub and bearing assembly. 13. Install tire and wheel assembly, aligning previous marks. 14. Lower vehicle and torque wheels. CAUTION: Before moving vehicle, pump brake pedal several times to be sure it is firm. Do not move vehicle until a firm pedal is obtained. 15. Check brake operation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes Brake Caliper: Fundamentals and Basics Removal Notes When Removing the Caliper, Remember... - Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir is only 1/3 full. - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining thickness between wheels on the same axle will result in a strong steering pull when the brakes are applied. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. - When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is forced back into the caliper, these deposits will be forced back through the brake lines and into the master-cylinder. When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake fluid will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to "shoot" brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose and a glass or plastic jar to catch the expelled fluid. - Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses can be damaged easily by this practice. These hoses are double walled, damage to the interior pressure hose will not be visible. - Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not attempt to insert the piston back into the caliper. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 3533 Brake Caliper: Fundamentals and Basics Installation Notes WHEN INSTALLING CALIPERS AND PADS, REMEMBER... - Clean and lubricate caliper slide joint/pins with high temperature silicone grease: Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted movement of the caliper slide assemblies to release the brakes. If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon the release of the brake pedal. This will result in overheated brakes and premature brake wear. Disc Brake Mechanical Force Diagram NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel forces the inner pad against the rotor, then further travel forces the movable part of the caliper to pull the outer pad against the rotor. High temperature silicone lubricant must be used. Low temperature grease can melt and contaminate the pads and rotors, or can bake into a very hard substance which binds the slides. Petroleum based grease can cause the slide boots to soften and swell. Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. Anti-squeal Coating - Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an insulator to dampen high frequency vibrations that are generated during normal braking. These compounds are highly effective in preventing brake squeal. - Many professional repair shops recommend always rebuilding or replacing the calipers when replacing the brake linings, because: When the pistons are forced back into the calipers, the piston seals are dragged across any corrosion or abrasives that may be deposited on the inside of the caliper. Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston is gradually withdrawn from the caliper. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 3534 This results in the piston seals again being dragged across the layer of corrosion and deposits. Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking. - Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck bleeder screw is much easier with the caliper removed from the vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Testing and Inspection Brake Pad: Testing and Inspection Remove one of the front wheels and inspect the brake disc, caliper and linings. Do not get any oil or grease on the linings. It is recommended that all linings be replaced in sets when worn or damaged. If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > identifying Pad Types Brake Pad: Service and Repair identifying Pad Types Tab Mounted Outboard Pads TAB MOUNT The outboard brake pad is positioned onto the caliper with 2 metal tabs. SPRING MOUNT The outboard brake pad is positioned onto the caliper with a shoe spring (33). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > identifying Pad Types > Page 3540 Brake Pad: Service and Repair Removal Tab Mount Disc Brake Caliper Compressing Piston Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > identifying Pad Types > Page 3541 1. Remove the caliper assembly. Refer to Brake Caliper Removal. See: Brake Caliper/Service and Repair/Caliper Removal 2. Remove shoe and lining assemblies from caliper. To remove outboard shoe and lining use 12-inch adjustable pliers to straighten bent over shoe tabs. 3. Remove sleeves from mounting bolt holes. 4. Remove bushings from grooves in mounting bolt holes. 5. Position piston to bottom of bore. Spring Mount Removing Outboard Shoe & Lining Removing Inboard Shoe & Lining Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > identifying Pad Types > Page 3542 1. Remove caliper assembly. Refer to Brake Caliper Removal. See: Brake Caliper/Service and Repair/Caliper Removal 2. Remove shoe and lining assemblies from caliper. ^ Insert screwdriver between shoe and caliper and disengage buttons on shoe from holes in caliper. 3. Remove sleeves and bushings from grooves in caliper mounting bolt holes. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > identifying Pad Types > Page 3543 Brake Pad: Service and Repair Installation TAB Mount Fig. 9 Installing Retainer Spring On Inboard Shoe Fig. 10 Positioning Screwdriver Between Outboard Shoe Flange & Hat Section Of Rotor Fig. 11 Positioning Hammer To Clinch Brake Pad Tabs 1. Lubricate new bushings with suitable grease, install bushings in caliper grooves, then insert sleeves through bushings. 2. Install retaining spring onto inboard shoe and lining assembly if equipped, then install inboard shoe into caliper housing. Shoe must lay flat against piston. 3. Install outboard shoe and lining assembly into caliper housing ensuring wear sensor is properly positioned. Back of shoe must lay flat against caliper. 4. Install caliper assembly. Refer to Caliper Removal. See: Brake Caliper/Service and Repair/Caliper Removal 5. Apply brakes several times to ensure caliper piston is extended and shoes are fully seated. CINCHING PROCEDURE 1. Wedge a large flat blade screwdriver between outboard shoe flange and hat section of rotor. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > identifying Pad Types > Page 3544 2. Hold outer pad against caliper with suitable clamp or by applying moderate pressure on brake pedal. 3. Position a ball peen hammer on outboard shoe tab, then using a larger brass hammer, lightly tap the ball peen hammer to bend the outboard shoe tab. Tabs must be bent around casting to approximately 45°. 4. After both tabs have been bent pressure should be released and outboard shoe should be locked into position. CAUTION: If an outboard shoe is removed from the caliper, or the tabs unclinched for any reason, then it will be necessary to replace the shoe and lining assemblies. Do not re-clinch outboard shoe locking tabs after having removed shoe from caliper. Spring Mount Spring Mounted Outboard Pad 1. Lubricate new bushings with suitable grease, install bushings in caliper grooves, then insert sleeves through bushings. 2. Install retaining spring onto inboard shoe and lining assembly then install inboard shoe into caliper housing. 3. Install outboard shoe and lining assembly into caliper housing ensuring wear sensor is properly positioned. Ensure buttons on shoe are properly engaged in holes in caliper. 4. Install caliper assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 3549 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 3550 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 3551 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 3552 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 3553 Brake Align Order Form Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 3554 Brake Rotor/Disc: Technical Service Bulletins Brakes - Rotor & Hub Flange Cleaning Tool Revision File In Section: 5 - Brakes Bulletin No.: 73-50-37 Date: January, 1998 INFORMATION Subject: Revision to J 42450 Tool; Proper Brake Rotor and Hub Flange Surface Cleaning Models: 1998 and Prior Passenger Cars and Light Duty Trucks - with Disc Brakes (Rotor and Hub Separate) This bulletin is being revised to update the following text. This bulletin is being issued to inform the dealer about a revision to tool J 42450 and reinforce the need for proper hub flange and brake rotor mating surface cleaning during service. Tool J 42450 is a cleaning pad arbor and pad system that fits over the wheel stud and cleans the portion of the hub surface that is very difficult to reach with normal rotary cleaning pads. Tool J 42450 is being revised to J 42450-A to improve the hook and loop material retention. Any dealer experiencing problems with tool J 42450 should contact Kent-Moore at 1-800-345-2233 for a revised arbor at no charge. Anytime the brake rotor has been separated from the hub bearing flange or if rotor machining is necessary, the rotor and hub should be marked to maintain the original position. Clean the hub flange of all dirt and foreign material using special tool J 42450 or J 42450-A. Clean both sides of the brake rotor hub using an aggressive (80 grit) abrasive sanding pad on a rotary disc. Properly cleaning the rotor surfaces before rotor machining or reassembly ensures that dirt and corrosion will not add lateral runout to the rotor. Proper cleaning of the hub flange will also minimize the stack-up of lateral runout. On reassembly, the rotor should be reinstalled aligning the marks made on disassembly. Always use a torque wrench or the appropriate Torque Socket found in J 39544-KIT on an impact wrench when installing the wheel and tire assembly. Torque all wheel nuts using the correct sequence and torque. Refer to the Tire and Wheel Sub-Section in the applicable Service Manual. Excessive torque or torque variation between wheel nuts may cause distortion of the hub and rotor mating surface. This distortion may cause lateral runout and lead to brake pulsation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 3555 Brake Rotor/Disc: Technical Service Bulletins Brakes - Change In Brake Feel After Rotor Refinishing Number: 91-133-5 5 Section: 5 Date: December 1990 Corporate Bulletin No.: 075003R Subject: CHANGE IN BRAKE EFFECTIVENESS AFTER DISC BRAKE ROTOR REFINISHING/PAD REPLACEMENT Model and Year: ALL PASSENGER CARS ALL LIGHT DUTY TRUCKS TO: ALL CHEVROLET DEALERS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-316-5, DATED AUGUST 1990. INFORMATION HAS BEEN ADDED REGARDING HUB AND ROTOR CLEANING, PROPER TORQUING TECHNIQUE, REVISED MACHINING TABLE, CHANGE SPECIFICATION FOR MAXIMUM SCORINGING DEPTH. THE 1991 MODEL YEAR WAS ALSO ADDED. ALL COPIES OF 90-316-5 SHOULD BE DISCARDED. Some comments have been received about a change in preceived braking effectiveness which occurs after rotors have been refinished and/or disc brake pads have been replaced. New lining materials have been formulated for increased lining life and to reduce brake squeal. Also, Federal regulations currently prohibit the use of asbestos in Original Equipment Manufactured (O.E.M.) front disc brake linings, and will totally ban asbestos from all O.E.M. brake linings in the near future. Due to these changes, initial rotor surface finish is more critical than in the past, and is required for good brake performance. Following are some recommended actions/procedures to assure proper performance of the brake systems on all vehicles after rotor and/or pad service has been performed: 1 . When performing routine brake maintenance such as replacing worn disc brake pads or shoes, DO NOT refinish disc brake rotors or drums unless: A. There is a brake pulsation condition present, and this pulsation is found to be caused by the brake rotors or drums, or B. The rotors and/or drums are excessively scored. Surface scoring that does not exceed 1.2 MM (0.050 in.) on rotors or drums should not affect brake operation. Before removing rotors from the hub assembly, mark the rotor and on wheel stud so that the rotor may be re-installed in the same position. If rotors are removed, it is very important that rust and scale be removed from the rotor and hub mating surfaces. Failure to do so may introduce excessive lateral runout when the rotor is mounted on the brake lathe, or when the rotor is re-installed to the hub. 2. When refinishing disc brake rotors, it is important that the brake lathe be in good operating condition and that all tools or bits are sharp. Recommended vibration dampeners and/or adaptors should be used and should be clean and free of nicks (remember, 1988-91 W models require the use of an adaptor, J37160, because of the two-piece design). The following table shows the recommended procedure for rotor machining: ROUGH CUT FINISH CUT Spindle Speed 150 RPM 150 RPM Depth of Cut (per side) 0.127 mm (0.005") 0.051 mm (0.002") Tool Cross Feed per Rev 0.152 mm - 0.254 mm 0.051 mm (0.002")Max (0.006" - 0.010") Vibration Damper Yes Yes Sand Rotors-Final Finish No Yes It is important that a rough and a finish cut be made. All brake lathes use a single-point cutting tool which is not capable of giving the necessary surface finish. A SECONDARY FINISHING OPERATION MUST BE PERFORMED TO OBTAIN THE NECESSARY SURFACE FINISH. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 3556 An acceptable finish can be obtained using the Ammco Model 8350 Safe Swirl Disc Rotor Grinder, or equivalent, using 120 grit sandpaper and sanding each rotor surface with moderate pressure for a minimum of 60 seconds with the rotor turning at 150 RPM. An alternate method is to use a sanding block with 150 grit sandpaper. With the rotor turning at approximately 150 RPM, sand each side for a minimum of 60 seconds using moderate pressure. After the rotor has been sanded, the surfaces must be cleaned with a solvent such as brake cleaning, denatured alcohol, or equivalent. THE FINISHED ROTOR SURFACE SHOULD BE AS CLOSE TO THAT OF A NEW ROTOR AS POSSIBLE. FAILURE TO OBTAIN THE BEST POSSIBLE ROTOR FINISH WILL AFFECT INITIAL BRAKING PERFORMANCE. CAUTION: ROTORS OR DRUMS SHOULD ALWAYS BE REPLACED IF TURNING WILL RESULT IN A ROTOR OR DRUM THAT DOES NOT MEET MANUFACTURER SPECIFICATIONS FOR MINIMUM ROTOR THICKNESS OR MAXIMUM DRUM DIAMETER. NOTICE: When re-installing tire and wheel assemblies, it is very important that proper procedures be followed when installing and torquing the wheel nuts: A. Finger start all wheel nuts. B. Tighten wheel nuts to specified torque (use the "star," or alternating nut pattern) using a torque wrench. DO NOT USE AN IMPACT WRENCH. UNEVEN AND/OR EXCESSIVE TORQUING OF THE WHEEL NUTS HAS BEEN FOUND TO DISTORT ROTORS, RESULTING IN PREMATURE CUSTOMER COMEBACKS FOR BRAKE PULSATION 3. After brake pads have been replaced and/or rotors have been refinished, it is recommended that the new braking surfaces be broken in, or burnished, to properly seat them. This can be accomplished by making 20 stops from 30 mph, using medium to firm pressure. Take care to avoid overheating the brakes. 4. It is strongly recommended that the correct, specified General Motors replacement part(s) be used when servicing G.M. vehicles. General Motors does not test non-G.M. parts for proper performance on G.M. vehicles. Therefore, the use of non-G.M. parts may result in unacceptable vehicle performance. It is also important that the correct G.M. part(s) be used in the correct G.M. application. For example, some "A" model disc brake pads ("A" Heavy) will fit on "C" and "H" models, but will not provide the same performance as the pads specified for use on C and H vehicles. It may seem preferable to stock fewer brake pad part numbers, but customer dissatisfaction may result if vehicle performance is affected. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Rotor Lateral Runout Correction Information > Page 3557 Brake Rotor/Disc: Technical Service Bulletins Brake Rotor - Revised Thickness Specifications Number: 93-106-5 Section: 5 Date: FEB. 1993 Corporate Bulletin No.: 335002 ASE No.: A5 Subject: BRAKE ROTOR SPECIFICATIONS Model and Year: 1991-93 CAVALIER, CORSICA AND BERETTA SERVICE UPDATE This bulletin is an update to Section 5, brake rotor specifications for the "J" and "L" series. Only the corrections are listed below for the 1991-93 service manuals. 1992 All "J", "L" Minimum thickness after refinish should be 19.08 mm (.751). 1993 All "J", "L" Maximum thickness should be 20.48 mm (.806). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 3558 Brake Rotor/Disc: Specifications All rotors have a discard dimension cast into them. This is a wear dimension and not a refinish dimension. Any rotor which does not meet the specification should be replaced. (JA1) LIGHT DUTY (FRONTS) (JA2/JA8) MEDIUM AND HEAVY DUTY (FRONTS) REAR Rotor Diameter 9.72 in 10.24 in 10.237 in Lateral Runout 0.004 in 0.004 in 0.004 in Thickness Variation 0.0005 in 0.0005 in 0.0005 in Rotor Thickness (Max) 0.885 in 1.043 in 0.494 in Minimum Thickness after Refinish 0.83 in 0.972 in 0.439 in Discard Thickness 0.815 in 0.957 in 0.425 in Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 3559 Brake Rotor/Disc: Testing and Inspection PURPOSE In the manufacturing of the brake rotor all the tolerances regarding surface finish, parallelism, and lateral runout are held very closely. The maintenance of these tolerances provide the surface necessary to prevent brake roughness. Light scoring of the rotor surface not in excess of 0.38 mm (0.015-inch) in depth is normal. This condition does not affect the brake operation. Some discoloration or wear of the disc surface is normal and does not require re-surfacing when linings are replaced. SPECIFICATIONS - See: Specifications LATERAL RUNOUT Lateral runout is the movement of the rotor from side to side as it rotates on the spindle. This could also be referred to as "rotor wobble". This movement causes the brake pad and piston to be knocked back into it's bore. This results in additional pedal travel and a vibration during braking. Checking Lateral Runout 1. Check that the wheel bearings are not loose or worn. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 3560 2. Attach a dial indicator to a solid non-rotating portion of the hub assembly or suspension. - The point of the styles must contact the rotor face about 25 mm (1-inch) from the rotor edge. 3. Move the rotor one complete rotation and observe the dial indicator. 4. Rotate the bezel on the dial indicator such that "0" is at the low deflection point. 5. Again rotate the rotor at least one complete turn and observe the needle deflection. Total needle deflection will equal lateral runout. - The lateral runout should not exceed 0.10 mm (0.004-inch). MINIMUM THICKNESS The thickness of a rotor is important for two reasons: 1. Rotors which are too thin are not able to properly absorb and release heat during heavy braking. This results in reduced braking capacity and brake fade. 2. Rotors worn below minimum thickness in combination with worn pads/linings can result in the caliper piston extending too far becoming cocked or jammed. Rotor thickness should be measured at the thinnest point on the rotor. Any rotor which is worn below its minimum thickness should be replaced. For accurate measurements, it is best to remove the caliper to allow for complete access to the inboard side of the rotor. For more information on how to use a disc brake micrometer see Fundamentals and Basics. See: Fundamentals and Basics Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 3561 PARALLELISM Parallelism is the measurement of the thickness of the rotor at 12 or more points around the circumference of the rotor. All measurements must be made at the same distance in from the edge of the rotor. Lack Of Parallelism Lack Of Parallelism The rotor thickness must not vary more than 0.013 mm (0.0005-inch) from point to point. MACHINING Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 3562 Since accurate control of the rotor tolerances is necessary for proper performance of the disc brakes, machining of the rotor should be done only with precision equipment. All brake rotors have a minimum thickness dimension cast into them. This dimension is the minimum wear dimension and not a refinish dimension. Do not use a brake rotor that will not meet the specifications, after refinishing. Replace with a new brake rotor. NOTE: 1 inch = 25.4mm, so if your micrometer measures in inches and the specified thickness on the disc is in millimeters, convert millimeters to inches by dividing the specified number of millimeters by 25.4. Example: Specification on disc is 17.8 mm. Dividing 17.8mm by 25.4mm/in = 17.8/25.4 = 0.70 inches. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Removal Brake Rotor/Disc: Service and Repair Removal 1. Raise and support vehicle. 2. Mark relationship of wheel to hub and bearing assembly to insure proper wheel balance upon reassembly. 3. Remove wheel and tire assembly. CAUTION: Support caliper with piece of wire to prevent damage to brake line 4. Remove caliper. Refer to Brake Caliper/Service and Repair/Caliper Removal.See: Brake Caliper/Service and Repair 5. Pull rotor off hub assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Removal > Page 3565 Brake Rotor/Disc: Service and Repair Installation 1. Slide rotor onto hub assembly. 2. Install caliper. Refer to Brake Caliper/Service and Repair/Caliper Installation.See: Brake Caliper/Service and Repair 3. Install wheel and tire assembly while noting alignment marks. 4. Lower vehicle and torque wheel nuts to 140 Nm (100 ft. lbs.). 6. Depress brake pedal. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Removal > Page 3566 Brake Rotor/Disc: Service and Repair Service Notes Checking Rotor For Lateral Runout Checking Rotor Lateral Runout Servicing of disc brakes is extremely critical due to the close tolerances required in machining the brake disc to insure proper brake operation. The maintenance of these close controls of the shape of the rubbing surfaces is necessary to prevent brake roughness. In addition, the surface finish must be non-directional and maintained at a micro inch finish. This close control of the rubbing surface finish is necessary to avoid pulls and erratic performance, and to promote long lining life and equal lining wear of both left and right brakes. In light of the foregoing remarks, refinishing of the rubbing surfaces should not be attempted unless precision equipment, capable of measuring in micro inches (millionths of an inch) is available. To check lateral runout of a disc, mount a dial indicator on a convenient part (steering knuckle, tie rod, disc brake caliper housing) so that the plunger of the dial indicator contacts the disc at a point one inch from the outer edge, Fig. 2. If the total indicated runout exceeds specifications, install a new disc. To check parallelism (thickness variation), mount dial indicators, Fig. 3, so the plunger contacts rotor approximately 1 inch from outer edge. If parallelism exceeds specifications, replace rotor. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints Brake Rotor/Disc: Fundamentals and Basics Notes, Warnings, and Hints WHEN INSTALLING A ROTOR/DISC, REMEMBER... Thoroughly clean the rotors with brake cleaner. - Any grease or brake fluid which comes in contact with the rotor should be thoroughly cleaned prior to installing the new pads/linings. - Grease and other contaminants become lodged in the microscopic pores of the rotor's surface. This prolongs the brake-in time of the new linings and contaminates the friction material. - Commercially produced aerosol brake cleaners should be used to clean the rotor. Unlike carburetor cleaner or other petroleum based solvents, brake cleaner does not leave a residue on the rotor's surface. Recheck the wheel bearings once the tires are installed. - With the vehicle raised and properly supported, grasp the tire at the top and bottom and attempt to rock them back and forth. There should be no detectable lateral (wobble) movement. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3569 Brake Rotor/Disc: Fundamentals and Basics Tightening Notes WHEN TIGHTENING LUG NUTS, REMEMBER... Always tighten the lug nuts to the correct torque specification. Lightly lubricate the studs with an anti-seize compound to ensure proper torque and prevent damage to the threads. Tighten in an alternating pattern around the wheel until the wheel is centered on the studs. Do your final tightening with a torque wrench. When servicing disc brakes it is very important to properly torque the wheel assembly. Lug nuts which are installed with an air impact tool are often over-torqued. This may distort the rotor and result in excessive lateral runout (rotor wobble) and a pedal pulsation upon braking. Recheck the wheel bearings once the tires are installed. With the vehicle raised and properly supported, grasp the tire at the top and bottom and attempt to rock them back and forth. There should be no detectable lateral (wobble) movement. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3570 Brake Rotor/Disc: Fundamentals and Basics How to Use A Micrometer CONSTRUCTION The spindle on a micrometer is moved in or out by rotating the thimble or ratchet. The thread pitch on the spindle is 40 threads per inch. A single full rotation of the thimble extends or retracts the spindle one thread or 1/40 of an inch (0.025, 25 thousands). The thimble is divided into 25 equal divisions. Rotating the thimble one division will extend or retract the spindle 1/25 of a thread. (1/25) x (1/40)inch = 1/1000 inch (0.001), one division on the thimble is equal to 0.001 inches. HOW TO READ As the thimble is rotated out it uncovers a scale on the sleeve. Each major division on the scale is 1/10 of an inch (0.100) Each major division is separated into 4 minor divisions, each equal to 25/1000 of an inch (0.025). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3571 A full rotation will move the thimble exactly one minor division on the sleeve. To read the micrometer you must add the measurement which is visible on the sleeve to the measurement which is showing on the thimble In the example the sleeve measurement is 0.250 inches and the thimble measurement is 0.017 inches. The total measurement is then equal to the two measurements combined, 0.267 inches. NOTES The accuracy and calibration of a micrometer can be altered easily by applying too much pressure to the spindle. Use the thimble to quickly rotate the spindle in until it is near the rotor. - Use the ratchet to rotate the spindle into contact with the rotor. - The ratchet has a built in slip which prevents excessive stress or pressure from developing. Calibrate the micrometer regularly. Most micrometers come with a precision dowel which allows for easy and accurate adjustments. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Customer Interest for Backing Plate: > 00-05-24-001 > Apr > 00 > Rear Drum Brakes - Sticking/Won't Release Backing Plate: Customer Interest Rear Drum Brakes - Sticking/Won't Release File in Section: 05 - Brakes Bulletin No.: 00-05-24-001 Date: April, 2000 TECHNICAL Subject: Snow Intrusion Into Rear Drum Brake Assemblies Models: 1985-87 Buick Somerset 1985-89 Buick Skyhawk 1985-98 Buick Skylark 1985-88 Cadillac Cimarron 1985-2000 Chevrolet Cavalier 1985-88 Oldsmobile Firenza 1985-91 Oldsmobile Cutlass Calais 1992-98 Oldsmobile Achieva 1985-94 Pontiac Sunbird 1985-98 Pontiac Grand Am 1995-2000 Pontiac Sunfire Condition: Some customers may comment that after operating their vehicle in snow and then parking the vehicle for an extended period, the rear brakes appear to remain applied. Cause: On rare occasions, light powdery snow may enter one or both of the vehicle's rear drum brake assemblies. If the vehicle is parked prior to the snow melt (water) being expelled, this may result in the rear brake shoe(s) adhering/freezing to the brake drum(s). Normally, the brake shoe(s) will break free of the drum upon placing the vehicle in gear. However, cases have been noted where vehicle movement has been restricted until the brake assemblies have had an opportunity to thaw. Correction: Replace existing rear brake backing plates with new backing plates, P/N 18015841. Refer to the Drum Brakes sub-section in the Service Manual for replacement procedures. Parts Information Parts are expected to be available from GMSPO, April 10, 2000. Warranty Information For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Backing Plate: > 00-05-24-001 > Apr > 00 > Rear Drum Brakes - Sticking/Won't Release Backing Plate: All Technical Service Bulletins Rear Drum Brakes - Sticking/Won't Release File in Section: 05 - Brakes Bulletin No.: 00-05-24-001 Date: April, 2000 TECHNICAL Subject: Snow Intrusion Into Rear Drum Brake Assemblies Models: 1985-87 Buick Somerset 1985-89 Buick Skyhawk 1985-98 Buick Skylark 1985-88 Cadillac Cimarron 1985-2000 Chevrolet Cavalier 1985-88 Oldsmobile Firenza 1985-91 Oldsmobile Cutlass Calais 1992-98 Oldsmobile Achieva 1985-94 Pontiac Sunbird 1985-98 Pontiac Grand Am 1995-2000 Pontiac Sunfire Condition: Some customers may comment that after operating their vehicle in snow and then parking the vehicle for an extended period, the rear brakes appear to remain applied. Cause: On rare occasions, light powdery snow may enter one or both of the vehicle's rear drum brake assemblies. If the vehicle is parked prior to the snow melt (water) being expelled, this may result in the rear brake shoe(s) adhering/freezing to the brake drum(s). Normally, the brake shoe(s) will break free of the drum upon placing the vehicle in gear. However, cases have been noted where vehicle movement has been restricted until the brake assemblies have had an opportunity to thaw. Correction: Replace existing rear brake backing plates with new backing plates, P/N 18015841. Refer to the Drum Brakes sub-section in the Service Manual for replacement procedures. Parts Information Parts are expected to be available from GMSPO, April 10, 2000. Warranty Information For vehicles repaired under warranty, use as shown. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Page 3586 Backing Plate: Testing and Inspection Inspect backing plate shoe contact surface for grooves that may restrict shoe movement and cannot be removed by lightly sanding with emery cloth or other suitable abrasive. If backing plate exhibits above condition, it should be replaced. Also inspect for signs of cracks, warpage and excessive rust, indicating need for replacement. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal Backing Plate: Service and Repair Removal Wheel Cylinder NOTE: If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 1. With wheel and brake drum removed, remove brake shoe assemblies. Refer to Brake Shoe/Service and Repair/ Removal. See: Brake Shoe/Service and Repair/Removal CAUTION: Do not pull metal line away from cylinder, as this may kink or bend line. Brake fluid will damage painted surfaces. Brake fluid can also damage electrical connections. Shop cloths and clean containers should be used to prevent spillage of brake fluid. 2. Disconnect hydraulic line at wheel cylinder. Line will separate from cylinder when backing plate is removed. 3. Plug opening in line to prevent fluid loss and contamination. 4. Remove parking brake cable from backing plate. 5. Remove the 4 bolts which attach the hub bearing assembly to the axle. This will allow hub assembly and backing plate removal. 5. Remove Anti-Lock Brake (ABS) wheel speed sensor wire connector. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal > Page 3589 Backing Plate: Service and Repair Installation Wheel Cylinder 1. Install backing plate to axle assembly. 2. Install hub and bearing assembly with bolts. ^ Tighten bolts to 63 Nm (47 lbs. ft.). 3. Install hydraulic line at wheel cylinder. ^ Torque inlet tube nut to 17 Nm (12 lbs. ft.). 4. Install parking brake cable to backing plate. 5. Install brake components. Refer to Brake Shoe/Service and Repair/Installation.See: Brake Shoe/Service and Repair/Installation 6. Install wheel and tire assembly. 7. Bleed brakes. 8. Adjust rear brakes. Refer to Brake Shoe/Adjustment.See: Brake Shoe/Adjustments 9. .Adjust parking brake. Refer to Parking Brake/Adjustments. See: Parking Brake System/Adjustments Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications All drums have a discard dimension cast into them. This is a wear dimension and not a refinish dimension. Any drum which does not meet the specification should be replaced. Inside Diameter 7.879 in Runout 0.006 in Maximum Re-bore Diameter 7.899 in Discard Diameter 7.929 in Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 3593 Brake Drum: Testing and Inspection VISUAL INSPECTION Inspect the drum for cracks. If any large, through-the-drum cracks are located the drum must be replaced. NOTE: Cracks in drums are often difficult to locate. To quickly determine if a drum is cracked lightly drop the drum (from a height of 4-5 inches) onto a flat hard surface. A cracked drum will make a dull thud sound while a good drum will make a ringing sound. Inspect for signs of overheating. An overheated drum will often be discolored (blue/gold), warped, or heat checked. Heat checks are small cracks in the drum friction surface. If drums are cracked or heat spotted, they must be replaced. NOTE: The cause of the overheating should be determined prior to replacing the shoes/linings or drums. Inspect for scoring. Any grooves or scores in excess of 0.008 inches should be resurfaced. SPECIFICATIONS - See: Specifications MAXIMUM DIAMETER Purpose The thickness of the drum friction surface is directly proportional to the drums ability to absorb and release heat during braking. As the drum becomes thinner due to normal wear and resurfacing it looses its ability to absorb and release heat and is more prone to brake fade, distortion, and cracking. As the drum wears the inside diameter of the drum increases. The amount of drum thickness lost to wear is equal to 1/2 the increase in diameter. There are two specifications related to drum thickness. Discard Diameter - This is the maximum diameter at which it becomes unsafe to operate. A drum which has reached this thickness should not be machined and should be discarded. Maximum Rebore - This is the maximum diameter to which a drum may be machined or resurfaced to. This diameter is smaller (thicker) than the Discard diameter because it assumes the drum will need to have a sufficient thickness left, after machining, to allow for further wear from a new set of shoes/linings. Which One Should Be Used? If you install a new pair of shoes with the drum diameter at or less than the "Maximum Rebore" specification the drums should have a sufficient thickness to last the normal life of the new shoes/linings. The "Discard Diameter" should be used to determine if a drum needs to be replaced at the present time of inspection. If you install a new pair of shoes with the drums machined at or near "Discard Diameter", within a short time the drums will be too thin Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 3594 (unsafe) and the new shoes/linings will be subject to overheating and brake fade. How To Measure NOTE: For additional information on how to use a drum micrometer see Fundamentals and Basics. See: Fundamentals and Basics - A drum micrometer is used to measure the drum diameter. - The micrometer scale should be initially set to the original (new) thickness of the drum. - The base of the micrometer should be placed in the deepest groove in the drum and held steady while the measuring point is swiveled to find the maximum diameter. - The base and measuring point should be kept at the same depth in the drum. Drum Micrometer - The measurement should be repeated at 3 or more places around the circumference of the drum to determine if the drum is out of round. If the measurements differ by more than 0.004 inches the drum should be resurfaced. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 3595 NOTE: A drum which is out of round will cause a pedal pulsation to be felt upon braking. NOTE: A slight pedal pulsation during server braking is normal for vehicles equipped with Anti-Lock Brake systems. - The measurement should also be repeated at various depths of the drum to check for a bellmouth condition. If the measurements differ by more than .006 inches the drum should be resurfaced. NOTE: 1 inch = 25.4mm, so if your micrometer measures in inches and the specified thickness on the disc is in millimeters, convert millimeters to inches by dividing the specified number of millimeters by 25.4. Example: Specification on disc is 17.8 mm. Dividing 17.8mm by 25.4mm/in = 17.8/25.4 = 0.70 inches. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal Brake Drum: Service and Repair Removal For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Adjusting Brakes 1. Raise vehicle and support on jack stands. 2. Mark relationship of wheel to axle flange, then remove wheel and tire assembly. 3. Mark relationship of brake drum to axle flange. 4. Remove brake drum. If difficulty is encountered in removing the brake drum, the following steps may be of assistance. ^ Make sure parking brake is released. ^ Back off parking brake cable adjustment. ^ Back off brake adjustment. Refer to Brake Shoe/Adjustments.See: Brake Shoe/Adjustments ^ Use a small amount of penetrating oil applied around the drum pilot hole. ^ Use a rubber mallet to tap gently on outer rim of the drum and/or around inner drum diameter by spindle. Take care not to deform the drum by use of excessive force. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal > Page 3598 Brake Drum: Service and Repair Installation For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Measuring Brake Drum Inside Diameter Adjusting Brake Shoe To Drum Clearance 1. If brake shoes have been replaced or the adjusting screw has been moved the shoes should be adjusted. To do this use a suitable brake drum to shoe gauge, measure brake drum inside diameter. Adjust brake shoes to dimension obtained on outside portion of gauge. Refer to Brake Shoe/Adjustments.See: Brake Shoe/Adjustments 2. Install the brake drum. 3. Install the tire and wheel assembly while noting alignment marks. 4. Lower vehicle and torque wheel nuts to 140 Nm (100 ft. lbs.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Fundamentals and Basics > How to Read A Brake Drum Micrometer Brake Drum: Fundamentals and Basics How to Read A Brake Drum Micrometer HOW TO READ On a standard micrometer each division on the scale is equal to 0.001 inches. To obtain the total drum diameter the measurement shown on the dial is added to the value for which the micrometer scale is set. NOTE: When the dial is at 0.0 the dial indicator styles is fully inserted. When the styles is fully withdrawn the dial is at its maximum value. EXAMPLES In example "A" a new 10 inch drum is being measured. The micrometer scale is set to 10 inches, the styles is fully inserted, and the dial indicates 0.0. The drum diameter is 10.000 inches. In example "B" an older worn 10 inch drum is being measured. The micrometer scale is still set to 10 inches but now the styles is only partially inserted and the dial indicates 90. The total drum diameter is equal to 10.090 inches. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Fundamentals and Basics > How to Read A Brake Drum Micrometer > Page 3601 Brake Drum: Fundamentals and Basics Notes, Warnings, and Hints DRUM REMOVAL The drum should just slide off however it will often bind or stick for the following reasons: Excessive Grooves or Scoring - The interlocking grooves prevent the drum from sliding off. Uneven Wear - Uneven wear across the surface of the shoe creates a wedge which prevents the drum from sliding off. Lip or Edge - Commonly there will be a lip worn at the edge of the drum where the shoe to drum contact stops. NOTE: If both drums are stuck tightly, verify the parking brake is released. To remove a drum which is stuck you should retract the shoes by backing off the automatic adjuster. If the drum still will not slide off there may be corrosion between the drum and hub. A few sharp blows from a mallet or hammer along the front flat surface of the drum will usually free the drum. CAUTION: Prying off a stuck drum with a puller or pry bar can damage the springs or hardware. Always attempt to withdraw the shoes with the automatic adjuster first. Once the drum is removed a layer of brake dust will remain in the bottom of the drum. This dust should be thoroughly soaked with water or brake cleaner and then removed from the drum. WARNING: Inhaling brake dust is extremely hazardous to your health. DRUM INSTALLATION - Prior to installing the drum verify the automatic adjuster operates properly and that the tools you are intending to use to adjust the brakes will be able to reach the adjuster. - With the drum off, practice operating the adjuster through the access hole in the backing-plate. This will make adjusting the brakes much easier once the drum is installed. Ensure the shoes/linings are centered on the backing-plate (top to bottom and side to side). The drum will be very difficult to slide on if the shoes/linings are not centered. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Fundamentals and Basics > How to Read A Brake Drum Micrometer > Page 3602 If the drum was resurfaced, verify that all metal shavings have been removed. - If the wheel cylinders were replaced or overhauled, verify that the pistons are fully compressed. Newly installed or rebuilt wheel cylinders may initially stick in the extended position (prior to bleeding the system). Using brake assembly lubricant when overhauling the wheel-cylinder will help prevent this. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Description and Operation Brake Shoe: Description and Operation Brake Drum Assembly DUO-SERVO BRAKES The anchor plate drum brakes are called duo-servo design. In the duo-servo drum brake, the force that the wheel cylinder applies to the primary shoe is multiplied by the primary lining friction to provide a very high force applied to the secondary shoe. Torque from the brake shoes is transferred to the anchor pin and through the backing plate, to the axle flange. Adjustment is automatic when the brakes are applied while the car is backing up. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Description and Operation > Page 3606 Brake Shoe: Testing and Inspection Inspect brake linings for excessive wear, damage, oil, grease or brake fluid contamination. If any of the above conditions exists, brake linings must be replaced. Brake shoes must always be replaced as an axle set to maintain equal braking forces. Examine brake shoe webbing, hold-down and return springs for signs of overheating indicated by a slight blue color. If any component exhibits signs of overheating, replace hold-down and return springs with new ones. Overheated springs lose their pull and could cause brake linings to wear out prematurely. Inspect all springs for sags, bends and external damage, and replace as necessary. Inspect hold-down retainers and pins for bends, rust and corrosion. If any of the above conditions exist, replace retainers and pins. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Description and Operation > Page 3607 Brake Shoe: Adjustments The rear drum brakes, have self-adjusting shoe mechanisms that assure correct lining-to-drum clearances at all times. The automatic adjusters operate only when the brakes are applied as the vehicle is moving rearward. Although the brakes are self-adjusting, an initial adjustment is necessary after the brake shoes have been replaced, or when the length of the star wheel adjuster has been changed during some other service operation. 1. Raise and support vehicle, then remove rear wheels and brake drums. 2. Check to make sure that parking brake cable linkage and levers on secondary brake shoe are in ``free'' position. Measuring Brake Drum Inside Diameter Adjusting Brake Shoe To Drum Clearance Brake Adjustment Using Tool J-21177 3. Using tool J-21177, measure brake drum inside diameter. 4. Turn brake adjusting screw to expand shoes to diameter obtained on outside caliper portion of tool J-21177. 5. Install drums. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Description and Operation > Page 3608 CAUTION: Whenever rear drum brakes are serviced, the parking brake linkage cable at the equalizer must always be readjusted to prevent possible damage to brake shoes. 6. Adjust parking brake. Refer to Parking Brake Adjustment. See: Parking Brake System/Adjustments 7. Install wheels and tires and lower vehicle to floor. 8. Drive vehicle alternately forward and backward, applying brakes moderately, to obtain satisfactory pedal height. Adjusting Brakes . Brake Adjustment Determined By Drag 1. Remove adjusting hole knockout plate from brake drum and back off adjusting screw using screwdriver and adjusting tool. NOTE: The knockout plate must be drilled out using a 11 mm (7/16 inch) drill. After adjustment, install rubber adjusting hole cover GM P/N 5464803 or equivalent into adjusting hole to prevent dirt or contamination from entering drum brake assembly. 2. Using suitable tool, turn brake adjusting screw to expand brake shoes at each wheel until wheel can just be turned by hand. Drag should be equal on all wheels. 3. Back off adjusting screw at each wheel 33 notches. NOTE: Brakes should have no drag after the screw has been backed off about 15 notches. If a heavy drag is present check the parking brake cable for free operation. The brake lever must return to the released position without sticking or binding. 4. Install adjusting hole cover in brake backing plate. CAUTION: Whenever rear drum brakes are serviced, the parking brake linkage cable at the equalizer must always be readjusted to prevent possible damage to brake shoes. 5. Adjust parking brake. Refer to Parking Brake Adjustment.See: Parking Brake System/Adjustments 6. Install wheels and tires and lower vehicle to floor. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Description and Operation > Page 3609 7. Drive vehicle alternately forward and backward, applying brakes moderately, to obtain satisfactory pedal height. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal Brake Shoe: Service and Repair Removal For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Brake Drum Assembly Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal > Page 3612 Adjusting Brakes 1. Raise vehicle and support on jack stands. 2. Mark relationship of wheel to axle flange, then remove wheel and tire assembly. 3. Mark relationship of brake drum to axle flange. 4. Remove brake drum. If difficulty is encountered in removing the brake drum, the following steps may be of assistance. ^ Make sure parking brake is released. ^ Back off parking brake cable adjustment. ^ Remove adjusting hole knockout plate from brake drum and back off adjusting screw using screwdriver and adjusting tool. Use a small amount of penetrating oil applied around the drum pilot hole. NOTE: The knockout plate must be drilled out using a 11 mm (7/16 inch) drill. After adjustment, install rubber adjusting hole cover GM P/N 5464803 or equivalent into adjusting hole to prevent dirt or contamination from entering drum brake assembly. ^ Use a rubber mallet to tap gently on outer rim of the drum and/or around inner drum diameter by spindle. Take care not to deform the drum by use of excessive force. 5. Remove return springs (1 and 2) using J 8049, J 29840 or equivalent pliers. For additional information on brake spring removal and installation see Fundamentals and Basics. See: Fundamentals and Basics 6. Remove hold-down springs (3) and pins (5) using suitable pliers. 7. Remove actuator link (6) while lifting up on actuator lever (7). 8. Remove actuator lever (7), lever return spring (8) and bearing sleeve (4). 9. Remove parking brake strut (9) and strut spring (10). 10. Remove shoe and lining assemblies (11 and 12) after disconnecting parking brake cable. 11. Remove adjusting screw assembly (16) and adjusting screw spring (13). 12. Remove retaining ring (17), pin (18) and parking brake lever (19) from secondary shoe (12). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal > Page 3613 Brake Shoe: Service and Repair Installation For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Brake Drum Assembly Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal > Page 3614 Adjusting Brakes Adjuster Screw Assembly CLEAN AND INSPECT Wash all brake hardware in clean denatured alcohol. Clean adjusting screw (16) threads with a wire brush. Inspect threads of adjusting screw (16) for smooth rotation over full length. If any parts are of doubtful strength or quality due to discoloration from heat, over-stress, or are worn, the parts should be replaced. INSTALLATION 1. Apply brake lubricant P/N 1052196 or equivalent to the adjusting screw (4) threads, inside diameter of socket (3) and socket face. ^ Adequate lubrication is achieved when a continuous bead of lubricant is at open end of pivot nut (5) and socket (3) when threads are fully engaged. 2. Install parking brake lever (19) on secondary shoe (12) with pin (18) and retaining ring (17). For additional information on brake spring removal and installation see Fundamentals and Basics. See: Fundamentals and Basics 3. Install adjusting screw assembly and adjusting screw spring (13). 4. Install shoe and lining assemblies (11 and 12) after attaching parking brake cable. 5. Install parking brake strut (9) and strut spring (10) by spreading shoes (11 and 12) apart. To be properly positioned: ^ The end without the strut spring (10) should engage the parking brake lever (19) and secondary shoe and lining (12). ^ The end with the strut spring (10) should engage the primary shoe and lining (11). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Removal > Page 3615 NOTE: In the next step, bearing sleeve (4) must be installed between the secondary shoe and lining (12) and the actuator lever (7). 6. Install bearing sleeve (4), actuator lever (7) and lever return spring (8). 7. Install hold-down pins (5) and hold-down springs (3). 8. Install actuator link (6) on anchor pin (32). 9. Install actuator link (6) into actuator lever (7) while holding up on lever. 10. Install shoe return springs (1 and 2) using J 8057 pliers or equivalent. 11. Adjust Brakes. Refer to Brake Shoe/Adjustments.See: Adjustments Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Fundamentals and Basics > Brake Spring Removal and Installation Brake Shoe: Fundamentals and Basics Brake Spring Removal and Installation HOLD-DOWN SPRINGS Purpose Hold-down springs hold the shoes/linings against the backing-plate. The springs provide a flexible grip so that the shoes/linings will still be able to slide back and forth across the surface of the backing-plate. Tools Needed Specialized brake spring tool or - Pliers / needle nose locking pliers - Duct Tape (optional) Removal The hold-down spring must first be compressed so that the tip of the retaining pin is cleared of the spring. - The spring is then rotated so that the slot in top of the spring lines up with the tip of the retaining pin. NOTE: Be sure to hold the retaining pin from the rear of the backing-plate to prevent the pin from rotating with the spring. - The hold-down spring can then be released and the pin should slide through the slot in the top of the spring. - A specialized brake spring tool makes the job very simple. The tool firmly grips the surface of the hold-down spring while providing a clear view of the pin/slot relationship. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Fundamentals and Basics > Brake Spring Removal and Installation > Page 3618 Hold-down Spring Tool Conventional pliers or needle nose locking pliers will work if a brake spring tool is not available. - Grasp the top the the spring with the plier, compress, and rotate. CAUTION: Excessive pressure can easily distort the top of the spring. Any distortion widens the slot which can cause the pin to pop out during normal operation. If the slot appears distorted or widened it must be replaced. Installation While holding the brake shoe against the backing-plate, insert the retaining pin from the rear of the backing-plate through the appropriate hole in the brake shoe webbing. Verify the shoe is resting squarely on the contact pads of the backing-plate. NOTE: A strip of duct tape placed across the backside of the pin and backing-plate will help keep the pin from inadvertently falling falling out and will free up a hand to help steady the shoe during the next step. - Place the hold-down spring and washers over the pin. - With the thumb of one hand hold the shoe steady while reaching around the backing-plate to hold the retaining pin steady. - Use your other hand to simultaneously compress and align the slot of the hold-down spring with the pin. - When the slot and pin are aligned, further compress the spring to clear the tip of the pin and then rotate the spring 90 degrees. - The slot and tip of the pin should now be opposing each other at a 90 degree angle. - Verify the tip of the retaining pin is locked into the indents on the surface of the hold-down spring. This will keep the retaining pin from twisting and inadvertently popping out. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Fundamentals and Basics > Brake Spring Removal and Installation > Page 3619 RETURN SPRINGS Purpose Drum brake systems maintain a constant residual pressure on the wheel cylinders. Return springs overcome this residual pressure and keep the shoes/linings from contacting the drum when not in use. Return springs also overcome the resistance encountered by the shoes/linings as they are retracted across the contact pads on the backing-plate. Return springs can be separated into two categories, shoe-to-shoe and shoe-to-anchor pin. Tools Needed To remove and install return springs, three separate tool are useful. These three tools are often combined into a single pair of "brake pliers". Return Spring Tool Shoe-to-Anchor Pin These springs are attached at the brake shoe webbing (two 90 degree bends in the shank of the spring slide through and under webbing) and hook around the anchor pin. Removal A brake spring tool is inserted over the top of the anchor pin and rotated - As you rotate the tool a notch on the bottom side of tool slides under the spring and lifts it up and over the anchor pin. - The other end of the spring should now just pull up and out of the hole in the brake shoe webbing. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Fundamentals and Basics > Brake Spring Removal and Installation > Page 3620 NOTE: Carefully note the color of the spring and which hole it came out of. Liquid typewriting eraser or nail polish can be very useful in marking the appropriate hole for later installation. Installation Install the spring into the brake shoe webbing first. The two 90 degree bends should slide into the hole and lie flat, locking the spring to the webbing. - Slide the brake spring tool through the looped end of the spring and then hook the notched end of the tool over the anchor pin. - Pivot the tool upwards to stretch the spring over the anchor pin (a light film of grease on the backside of the brake tool will help the spring slide over and onto the anchor pin). - Be careful not to over-extend the spring. WARNING: Do not attempt to help the spring over the anchor pin with your fingers. Should the return spring slip off the tool it could seriously lacerate your hand. Shoe-to-Shoe Return Springs Removal Note the color and relationship of the spring and the holes in the brake shoe webbing it is attached to. - Using a pair of brake spring pliers, slide the hooked end of the pliers around and under one end of the spring. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Fundamentals and Basics > Brake Spring Removal and Installation > Page 3621 - Place the pointed tip of the pliers onto the brake shoe lining surface directly across from the spring (if the shoes are to be reused, place the tip into a rivet hole or place a thin sheet of wood between the linings and pointed tip). - Squeeze the pliers and lift the return spring from the hole. - Release the pliers slowly and remove the other end of the spring. Installation Use the same technique for installing the spring as was used for removing it. - If a rivet hole is not available, place a thin sheet of wood between the lining and pointed end of the tool. - A pair of needle nosed pliers may be helpful for guiding the end of the return spring into the hole. WARNING: Do not attempt to help the spring into the hole with your fingers. Should the return spring slip off the tool it could seriously lacerate your hand. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Fundamentals and Basics > Brake Spring Removal and Installation > Page 3622 Brake Shoe: Fundamentals and Basics Notes, Warnings, and Hints PRIOR TO REMOVING THE SHOES - Clean the shoes, hardware, and backing-plate thoroughly for the following reasons. Initially the springs will appear black (from brake dust). The springs are actually color coded and it is very important to reinstall the springs in the correct location. - The shoes and hardware will need to be cleaned to determine if an overheating condition has occurred (discolored bluish-purple). - Inhaling brake dust is VERY HAZARDOUS TO YOUR HEALTH. WARNING: Do not use compressed air to clean the brake assembly. - Verify the Leading and Trailing shoes are installed in the correct relationship. - Verify the new brake components exactly match the old ones. DURING REMOVAL - If there is any possibility that the shoes may reused, remove any drip pans that may be under the brake assembly and handle the shoes carefully when removing. NOTE: WORK ON ONE SIDE AT A TIME (unless you are very familiar with the system). The other side may then be used as a model for reassembling. INSTALLATION - Clean and lubricate the backing-plate contact pads with a high temperature silicone lubricant. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Fundamentals and Basics > Brake Spring Removal and Installation > Page 3623 - Verify the Leading and Trailing shoes are installed in the correct relationship. - Any contamination should be removed from the new shoes immediately. If very light hand sanding will not remove the contamination the shoes should be discared. - When replacing shoes/linings or drums always replace both sides per axle. If only one side is replaced a steering pull may develop during braking. - If brake hardware is being replaced, verify that both the color and shape of the new springs match the old springs. - Prior to reinstalling the drum, the automatic adjuster will need to be backed off to accommodate for the increased thickness of the new shoes/linings. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder To Backing Plate 15 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal Wheel Cylinder: Service and Repair Removal For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Wheel Cylinder 1. Raise vehicle and support on jack stands. 2. Mark relationship of wheel to axle flange, then remove wheel and tire assembly. 3. Mark relationship of brake drum to axle flange. 4. Remove brake drum. 5. Remove dirt and foreign material around wheel cylinder assembly inlet and pilot. CAUTION: Do not pull metal line away from cylinder, as this may kink or bend line. Line will separate from cylinder when cylinder is moved away from brake backing plate. 6. Disconnect hydraulic line at wheel cylinder. 7. Plug opening in line to prevent fluid loss and contamination. 8. Remove wheel cylinder bolts (21) using a #6 Torx socket. 9. Remove wheel cylinder. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 3629 Wheel Cylinder: Service and Repair Overhaul For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Wheel Cylinder Wheel Cylinder Components 1. Remove boots (22), pistons (23) and seals (24), spring assembly (25) and bleeder valve (20). 2. Clean all parts with brake fluid. 3. Inspect cylinder bore and pistons for scoring, nicks, corrosion and wear. Use crocus cloth to polish out light corrosion. ^ Replace wheel cylinder assembly if bore will not clean up with crocus cloth. ASSEMBLY NOTE: Ensure hands are clean before proceeding with assembly. 1. Clean all parts in clean denatured alcohol. 2. Dry parts with unlubricated compressed air. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 3630 3. Lubricate cylinder wall and rubber cups with clean brake fluid, then install spring assembly (25), seals (24), pistons (23) and boots (22). 4. Wipe end of hydraulic line to remove any foreign matter, then place wheel cylinder in position. Enter tubing into cylinder and start threads on fitting. 5. Secure cylinder to backing plate, then complete tightening of tubing fitting. Torque to 17 Nm (12 lbs. ft.). 6. Install bleeder valve (20). Torque to 7 Nm (65 lbs. in.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 3631 Wheel Cylinder: Service and Repair Installation For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Wheel Cylinder 1. Position wheel cylinder assembly (28) and hold in place with wooden block between cylinder and axle flange. 2. Install wheel cylinder bolts (21) using a #6 Torx socket. ^ Torque wheel cylinder bolts to 20 Nm (15 lbs. ft.). 3. Install inlet tube line and nut. ^ Torque inlet tube nut to 17 Nm (12 lbs. ft.). 4. Bleed the brake system. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Page 3632 Wheel Cylinder: Fundamentals and Basics REMOVAL - Wheel cylinder retaining bolts, brake line fittings, and bleeder screws are often heavily corroded. Prior to starting the job you should spray these with a penetrating oil. - A line (flare nut) wrench should be used when loosening the brake line fittings. These fittings round off easily. OVERHAUL - Light amounts of corrosion within the cylinder bore and on the piston may be removed with crocus cloth. - Pitting and heavy corrosion should be removed with a hone. When honing the hone should be inserted and withdrawn quickly to achieve a 45 degree crosshatch. - Closely inspect the areas of the cylinder where the pistons seals contact. It is very important these areas are absolutely free of deposits, corrosion, or pitting. - Remove the bleeder screw and verify that the passage is clear. - Leave the bleeder open when installing pistons and cups into the cylinder bore. If the bleeder is closed a large amount of air will be forced into the brake lines. - Use brake assembly lubricant to coat the cylinder bore, pistons, and cups. Clean brake fluid is an acceptable lubricant when assemblying the wheel-cylinder but brake assembly lubricant is much slicker and minimizes the chance that the cups will be damaged. WARNING: Do not use a petroleum based grease or oil to lubricate the wheel-cylinder components. This will cause the seals and cups to swell and deteriorate. - When reassemblying the wheel-cylinder it is helpful to follow this sequence: 1. Rear cup (verify the cup is inserted properly, flat side towards the piston, concave side towards the center) 2. Rear piston 3. Rear dust cap (this prevents the rear cup and piston from popping back out when the spring and front components are installed). 4. Spring 5. Front cup 6. Front piston 7. Front dust cap INSTALLATION Attach the brake fluid line fitting loosely to the wheel-cylinder prior to inserting and tightening the retaining bolts. The brake fluid line fitting is much easier to attach and start turning with the wheel-cylinder loose. WARNING: Don't forget to tighten the brake line fitting after the retaining bolts are tightened. - Leave the wheel-cylinder bleeder screw open and place a drip pan under the rear brake assembly. Refill the master-cylinder with new brake fluid and let the fluid gravity bleed through the open bleeder screw. When brake fluid begins to drip from the bleeder, close the bleeder screw. NOTE: The brake system will still need to be flushed and bled, but this makes starting the process much easier. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Hydraulic System Bleeding Brake Bleeding: Service and Repair Hydraulic System Bleeding Manual Bleeding Pressure bleeding is recommended for all non-ABS hydraulic systems. However, if a pressure bleeder is unavailable, use the following procedure. Brake fluid damages painted surfaces. Immediately clean any spilled fluid. 1. Remove vacuum reserve by pumping brakes several times with engine off. 2. Fill master cylinder reservoir with clean brake fluid. Check fluid level often during bleeding procedure; do not let reservoir fall below half full. 3. If necessary, bleed master cylinder as follows: a. Disconnect master cylinder forward brake line connection until fluid flows from reservoir. Reconnect and tighten brake line. b. Instruct an assistant to slowly depress brake pedal one time and hold. c. Crack open front brake line connection again, purging air from cylinder. d. Retighten connection and slowly release brake pedal. e. Wait 15 seconds, then repeat until all air is purged. f. Bleed the rearward (nearest the cowl) brake line connection by repeating steps a through e. 4. Loosen, then slightly retighten bleeder valves at all four wheels. Repair any broken, stripped or frozen valves at this time. 5. Proceed to appropriate wheel first and follow set sequence according to the bleeding sequence. Bleeding Sequence: RR-LF-LR-RF Fig. 20 Bleeding Brakes 6. Place transparent tube over bleeder valve, then allow tube to hang down into transparent container, Fig. 20. Ensure end of tube is submerged in clean brake fluid. 7. Instruct an assistant to slowly depress brake pedal one time and hold. 8. Crack open bleeder valve, purging air from cylinder. Retighten bleeder screw and slowly release pedal. 9. Wait 15 seconds, then repeat steps 7 and 8. Repeat these steps until all air is bled from system. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Hydraulic System Bleeding > Page 3638 Fig. 21 Installing Pressure Bleeder Adapter Fig. 20 Bleeding Brakes Pressure Bleeding, Non-ABS Only 1. Loosen, then slightly retighten bleeder valves at all four wheels. Repair any broken, stripped or frozen valves at this time. 2. Using a diaphragm type pressure bleeder, install suitable bleeder adapter to master cylinder, Fig. 21. 3. Charge bleeder ball to 20-25 psi. 4. Connect pressure bleeder line to adapter. 5. Open line valve on pressure bleeder, then depress bleed-off valve on adapter until a small amount of brake fluid is released. 6. Raise and support vehicle. 7. Proceed to appropriate wheel first and follow set sequence according to Wheel Bleeding Sequence. 8. Place transparent tube over bleeder valve, then allow tube to hang down into transparent container, Fig. 20. Ensure end of tube is submerged in clean brake fluid. 9. Open bleeder valve 1/2 to 3/4 turn and allow fluid to flow into container until all air is purged from line. Wheel Bleeding Sequence Rear wheel drive models except Corvette: if manual bleeding, RR-LR-RF-LF; if pressure bleeding, bleed front brakes together and rear brakes together. Front wheel drive models except Spectrum: RR-LF-LR-RF. 1989 Corvette: RF-RR-LR-LF. Spectrum: LF-RR-RF-LR. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Hydraulic System Bleeding > Page 3639 Flushing Hydraulic System If brake fluid is old, rusty or contaminated, or whenever new parts are installed in hydraulic system, the system must be flushed. Bleed brakes, allowing at least one quart of clean brake fluid to pass through system. Any rubber parts in hydraulic system which were exposed to contaminated fluid must be replaced. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Hydraulic System Bleeding > Page 3640 Brake Bleeding: Service and Repair Master Cylinder Bleeding This procedure can be performed with master cylinder on or off vehicle. CAUTION: Brake fluid will damage painted surfaces. Brake fluid can also damage electrical connections. Shop cloths and clean containers should be used to prevent spillage of brake fluid. 1. Disconnect brake lines at master cylinder, if necessary. 2. Connect suitable lengths of brake lines to master cylinder and immerse other ends of lines in master cylinder reservoirs. 3. Apply master cylinder pushrod or brake pedal with full strokes until air bubbles have disappeared in reservoirs. It may require 20-30 applications to fully eliminate air bubbles. 4. Remove bleeding lines from master cylinder, then install master cylinder on vehicle, if necessary, and connect brake lines. 5. Fill the reservoir. Normal bleeding procedures should be followed after the master cylinder is installed. For additional information see Bench Bleeding. See: Brake Master Cylinder/Fundamentals and Basics Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Page 3641 Brake Bleeding: Fundamentals and Basics BENCH BLEEDING Why A master-cylinder will develop little or no pressure if air is trapped in cylinder bore. Normal brake bleeding will not remove air trapped within the master-cylinder. How Clamp the master-cylinder securely in a vice. It is usually best to clamp the side of the vice onto the flat surface that is used to secure the master-cylinder to the brake booster. There are two basic methods for bleeding master-cylinder, one utilizes stroking the master-cylinder to expel air from the cylinder bore while the other utilizes a large syringe to backflush fluid from the outlet ports to the reservoir. Stroking Fill the master-cylinder with clean brake fluid. - The brake line fittings on the master-cylinder should be capped or plugged. NOTE: Special "bench bleeding" plastic fittings are available which allow for recirculating the brake fluid back into the reservoir. - Using a dull object, slowly stroke the master-cylinder piston, air and brake fluid will be expelled from the brake line fittings. Prior to releasing the piston plug or cap the outlet ports. - Repeat this procedure 8-10 times or until no air is emitted from the outlet ports. - When finished, cap the outlet ports and install the master-cylinder. Syringe Fill the syringe (one especially designed for brake bleeding) with clean brake fluid. - Insert the end of the syringe into one of the outlet ports on the master-cylinder. - Slowly compress the syringe and back flush the brake fluid through the master-cylinder. - A combination of air and brake fluid will be emitted from the inlet port in the fluid reservoir. - Repeat this procedure until only brake fluid is emitted into the reservoir. Cap the outlet ports and install the master-cylinder. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 92455 > Nov > 91 > Brakes (Front) Caliper Not Sliding Freely, Corrosion Brake Caliper: Customer Interest Brakes (Front) - Caliper Not Sliding Freely, Corrosion Number: 92-45-5 Section: 5 Date: NOV. 1991 Corporate Bulletin No.: 135017 ASE No.: A5 Subject: FRONT DISC BRAKE CALIPER BOLT BORE CORROSION Model and Year: 1990-92 CAVALIER, CORSICA AND BERETTA Condition: Some 1990-92 J/L cars may experience a condition of a caliper not sliding freely or moving on the mounting bolts inward toward the center of the vehicle. FIGURE 1 Cause: This condition is due to corrosion in the caliper mounting bolt area (See Figure 1) caused by contaminates seeping past the mounting bolt rubber bushing. Correction: Inspect the caliper suspension mounting bolts and sleeves for corrosion. Also, inspect the bushings for cuts, nicks and/or excessive wear. If damage to either part is found, replace with new parts. IMPORTANT: Do Not attempt to polish away corrosion from the bolt or sleeve assemblies. Lubricate the bushing bore with silicone grease, contained in Bushing Kit, P/N 18017226 or equivalent and install bolt and sleeve assembly. The bolt and sleeve assembly should slide through the bushing without the use of mechanical assistance. If the force required to slide the bolt and sleeve exceeds hand assembly pressure, remove the bushings and inspect the mounting bores for corrosion. * If bores show signs of corrosion, clean the bores with a one inch wheel cylinder honing brush. IMPORTANT: Replace rubber bushings with new parts contained in service kit, P/N 18017226 whenever they are removed from housing. Parts are currently available from GMSPO. Labor Operation Number: T1781 Labor Time: 1.2 Hours Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 92455 > Nov > 91 > Brakes (Front) - Caliper Not Sliding Freely, Corrosion Brake Caliper: All Technical Service Bulletins Brakes (Front) - Caliper Not Sliding Freely, Corrosion Number: 92-45-5 Section: 5 Date: NOV. 1991 Corporate Bulletin No.: 135017 ASE No.: A5 Subject: FRONT DISC BRAKE CALIPER BOLT BORE CORROSION Model and Year: 1990-92 CAVALIER, CORSICA AND BERETTA Condition: Some 1990-92 J/L cars may experience a condition of a caliper not sliding freely or moving on the mounting bolts inward toward the center of the vehicle. FIGURE 1 Cause: This condition is due to corrosion in the caliper mounting bolt area (See Figure 1) caused by contaminates seeping past the mounting bolt rubber bushing. Correction: Inspect the caliper suspension mounting bolts and sleeves for corrosion. Also, inspect the bushings for cuts, nicks and/or excessive wear. If damage to either part is found, replace with new parts. IMPORTANT: Do Not attempt to polish away corrosion from the bolt or sleeve assemblies. Lubricate the bushing bore with silicone grease, contained in Bushing Kit, P/N 18017226 or equivalent and install bolt and sleeve assembly. The bolt and sleeve assembly should slide through the bushing without the use of mechanical assistance. If the force required to slide the bolt and sleeve exceeds hand assembly pressure, remove the bushings and inspect the mounting bores for corrosion. * If bores show signs of corrosion, clean the bores with a one inch wheel cylinder honing brush. IMPORTANT: Replace rubber bushings with new parts contained in service kit, P/N 18017226 whenever they are removed from housing. Parts are currently available from GMSPO. Labor Operation Number: T1781 Labor Time: 1.2 Hours Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Page 3655 Brake Caliper: Specifications Caliper Mounting Bolts 38 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Page 3656 Brake Caliper: Description and Operation Disc Brake Caliper Assembly This caliper has a single bore and is mounted to the support bracket with two mounting bolts. Hydraulic pressure, created by applying force to the brake pedal, is converted by the caliper into friction. The hydraulic pressure is applied equally against the piston and the bottom of the caliper bore moving the piston outward, resulting in a clamping action on the brake rotor. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Page 3657 Brake Caliper: Testing and Inspection Honing caliper piston bore Should it become necessary to remove the caliper for installation of new parts, clean all parts in alcohol, wipe dry using lint free cloths, using an air hose to blow out drilled passages and bores. Check dust boots for punctures or tears. If punctures or tears are evident, new boots should be installed upon reassembly. Inspect piston bores in both housings for scoring or pitting. Bores that show light scratches or corrosion can usually be cleaned with crocus cloth. However, bores that have deep scratches or scoring may be honed, provided the diameter of the bore is not increased more than .002 inches. If the bore does not clean up within this specification, a new caliper housing should be installed (black stains on the bore walls are caused by piston seals and will do no harm). When using a hone be sure to install the hone baffle before honing bore. The baffle is used to protect the hone stones from damage. Use extreme care in cleaning the caliper after honing. Remove all dust and grit by flushing the caliper with alcohol. Wipe dry with clean lint free cloth and then clean a second time in the same manner. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal Brake Caliper: Service and Repair Caliper Removal For additional information see Removal Notes. See: Fundamentals and Basics Compressing Piston Compressing Caliper Piston NOTE: If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. CAUTION: Brake fluid will damage painted surfaces. Brake fluid can also damage electrical connections. Shop cloths and clean containers should be used to prevent spillage of brake fluid. 1. Remove approximately 2/3 of brake fluid from master cylinder. 2. Raise vehicle and support on jack stands. 3. Mark relationship of wheel to hub and bearing assembly. 4. Remove front wheels. 5. Reinstall two wheel nuts to retain rotor to hub and bearing assembly. 6. Position suitable pliers over outboard pad and housing as shown in image and squeeze pliers to compress caliper piston. This will provide clearance between linings and rotor. The piston can also be bottomed in the bore with a large C-clamp. Refer to image. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3660 Caliper Mounting Fig. 5 Removing Caliper Mounting Bolts Suspending Caliper NOTE: If removing caliper assembly only to access other brake parts do not remove brake inlet fitting as indicated in step 7. If the inlet fitting (11) is disconnected, caliper must be bled when reinstalling. 7. Remove bolt attaching inlet fitting (11) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3661 8. Plug openings in caliper housing (10) and inlet fitting (11) to prevent fluid loss and contamination. CAUTION: Do not crimp brake hose, as this may damage internal structure. 9. Remove caliper mounting bolts and sleeves (1). 10. Remove caliper (10) from rotor and caliper mounting bracket (12). ^ If the caliper assembly is not being removed from the vehicle for unit repair, suspend the caliper with a wire hook from the strut. Refer to image. 11, Inspect Caliper ^ Mounting bolts and sleeves (1) for corrosion. ^ Bushings (2) for cuts or nicks. ^ If damage to either part is found, replace with new parts when installing caliper. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3662 Brake Caliper: Service and Repair Caliper Overhaul 1. Remove caliper completely from vehicle 2. Clean outside of caliper, then drain brake fluid from caliper. WARNING: Do not place fingers in front of piston for any reason when applying compressed air. This could result in serious personal injury. Fig. 6 Applying Compressed Air To Caliper Line Port Disc Brake Caliper Assembly 3. Use clean shop towels to pad interior of caliper assembly, then remove piston by directing compressed air into caliper brake hose inlet hole. Use just enough air pressure to ease piston out of bore. 4. Remove piston (9) from the caliper. INSPECT ^ Piston for scoring, nicks, corrosion and worn or damaged chrome plating. Replace piston if any of these conditions are found. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3663 Removing Boot 5. Remove boot (6) from caliper housing bore. Be careful not to scratch housing bore. CAUTION: Do not use a metal tool to remove piston seal. This may damage caliper bore or seal groove. Caliper Assembly 6. Remove piston seal (10) from seal groove in caliper housing (12) bore with a small wood or plastic tool. INSPECT ^ Caliper housing bore and seal groove for scoring, nicks, corrosion and wear. 7. Use crocus cloth to polish out light corrosion. Replace caliper housing if corrosion in and around seal groove will not clean up with crocus cloth. 8. Remove bleeder valve (11) from caliper. 9. Clean all parts in clean, denatured alcohol. Dry with unlubricated compressed air. 10. Blow out all passages in caliper housing and bleeder valve. ASSEMBLY 1. Install bleeder valve into caliper. 2. Tighten bleeder valve to 13 Nm (10 lbs. ft.) 3. Lubricate all rubber parts with clean brake fluid prior to installation. 4. Install piston seal (10) into caliper seal groove. Be sure seal is not twisted. Installing Boot Onto Piston 5. Install boot onto piston. 6. Install piston and boot into bore of caliper and push to bottom of bore. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3664 Seating Boot Into Caliper Housing 7. Seat boot in caliper housing counterbore using J 29077-A or equivalent. 8. Install caliper. Refer to Caliper Installation. 1. Remove caliper completely from vehicle 2. Clean outside of caliper, then drain brake fluid from caliper. WARNING: Do not place fingers in front of piston for any reason when applying compressed air. This could result in serious personal injury. 3. Remove piston (5) from the caliper. 4. Use clean shop towels to pad interior of caliper assembly (10,) then remove piston by directing compressed air into caliper brake hose inlet hole. Use just enough air pressure to ease piston out of bore. INSPECT ^ Piston (5) for scoring, nicks, corrosion and worn or damaged chrome plating. Replace piston (5) if any of these conditions are found. 5. Remove boot (6) from caliper housing bore. Be careful not to scratch housing bore. CAUTION: Do not use a metal tool to remove piston seal in step 6. This may damage caliper bore or seal groove. 6. Remove piston seal (4) from seal groove (16) in caliper housing (10) bore with a small wood or plastic tool. INSPECT ^ Caliper housing (10) bore and seal groove (16) for scoring, nicks, corrosion and wear. 7. Use crocus cloth to polish out light corrosion. Replace caliper housing if corrosion in and around seal groove will not clean up with crocus cloth. 8. Remove bleeder valve (3) from caliper (1). 9. Clean all parts in clean, denatured alcohol. Dry with unlubricated compressed air. 10. Blow out all passages in caliper housing (10) and bleeder valve (3). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3665 Seating Boot Into Caliper Housing Caliper Assembly ASSEMBLY 1. Install bleeder valve (3) into caliper (10). 2. Tighten bleeder valve (3) to 13 Nm (115 lbs. in.) 3. Lubricate all rubber parts with clean brake fluid prior to installation. 4. Install piston seal (4) into caliper seal groove (16). Be sure seal is not twisted. 5. Install boot (6) onto piston (5). 6. Install piston (5) and boot (6) into bore of caliper and push to bottom of bore. 7. Seat boot (6) in caliper housing (10) counterbore using J 29077-A or equivalent. 8. Install bushings (2). 9. Lubricate beveled end of bushing with silicone grease, GM Part Number 1052863 or equivalent. 10. Pinch bushing and install bevel end first through housing mounting bore. 11. Install caliper. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3666 Brake Caliper: Service and Repair Caliper Installation For additional information see Installation Notes. See: Fundamentals and Basics Inboard Shoe And Retaining Spring Disc Brake Caliper Assembly Installing Outboard Shoe And Lining Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3667 1. Install inboard shoe and lining (7) by snapping shoe retaining sprlng (14) into piston (5) inside diameter. Shoe must lay flat against piston. 2. Install outboard shoe and lining (8) with wear sensor (9) at leading edge of shoe. During forward wheel rotation, the back of the shoe must lay flat against caliper. 3. Liberally coat inside diameter of bushings (2) with silicone grease. Caliper To Bracket Clearance 4. Position caliper assembly over disc and align mounting bolt holes (12). If brake hoses were not disconnected during removal, use care not to kink hoses during installation. 5. Install mounting bolts and tighten to 51 Nm (38 lbs. ft.). 6. Check clearance between caliper (10) and stops on the bracket (12). Clearance should be 0.13 to 0.30 mm (0.005 to 0.012 inch). If necessary, remove caliper and file ends of the stops on the bracket (12) to provide proper clearance. 7. Install inlet fitting, if removed and torque to 45 Nm (33 lbs. ft.). 8. Fill master cylinder. Bleed brake system if brake line was disconnected and recheck master cylinder fluid level. 9. Apply a firm force three times to brake pedal to seat linings. Clinching Procedure (Step 1) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 3668 Clinching Procedure (Step 2) 10. Pry up on outboard shoe with large flat-blade screwdriver or similar tool between outboard shoe flange and hat section of rotor. Keep tool wedged in place during the following step. 11. Hold moderate force on brake pedal and clinch outboard shoe tabs (13) using procedure shown in image. Outboard shoe should be locked tightly in position. 12. Remove wheel nuts securing rotor to hub and bearing assembly. 13. Install tire and wheel assembly, aligning previous marks. 14. Lower vehicle and torque wheels. CAUTION: Before moving vehicle, pump brake pedal several times to be sure it is firm. Do not move vehicle until a firm pedal is obtained. 15. Check brake operation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes Brake Caliper: Fundamentals and Basics Removal Notes When Removing the Caliper, Remember... - Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir is only 1/3 full. - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining thickness between wheels on the same axle will result in a strong steering pull when the brakes are applied. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. - When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is forced back into the caliper, these deposits will be forced back through the brake lines and into the master-cylinder. When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake fluid will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to "shoot" brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose and a glass or plastic jar to catch the expelled fluid. - Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses can be damaged easily by this practice. These hoses are double walled, damage to the interior pressure hose will not be visible. - Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not attempt to insert the piston back into the caliper. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 3671 Brake Caliper: Fundamentals and Basics Installation Notes WHEN INSTALLING CALIPERS AND PADS, REMEMBER... - Clean and lubricate caliper slide joint/pins with high temperature silicone grease: Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted movement of the caliper slide assemblies to release the brakes. If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon the release of the brake pedal. This will result in overheated brakes and premature brake wear. Disc Brake Mechanical Force Diagram NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel forces the inner pad against the rotor, then further travel forces the movable part of the caliper to pull the outer pad against the rotor. High temperature silicone lubricant must be used. Low temperature grease can melt and contaminate the pads and rotors, or can bake into a very hard substance which binds the slides. Petroleum based grease can cause the slide boots to soften and swell. Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. Anti-squeal Coating - Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an insulator to dampen high frequency vibrations that are generated during normal braking. These compounds are highly effective in preventing brake squeal. - Many professional repair shops recommend always rebuilding or replacing the calipers when replacing the brake linings, because: When the pistons are forced back into the calipers, the piston seals are dragged across any corrosion or abrasives that may be deposited on the inside of the caliper. Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston is gradually withdrawn from the caliper. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 3672 This results in the piston seals again being dragged across the layer of corrosion and deposits. Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking. - Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck bleeder screw is much easier with the caliper removed from the vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations Brake Fluid: Technical Service Bulletins Brake Fluid - Level & Filling Recommendations File In Section: 05 - Brakes Bulletin No.: 00-05-22-004 Date: May, 2000 INFORMATION Subject: Brake Fluid Level and Filling Recommendations Models: 2001 and Prior Passenger Cars and Trucks Many dealers and after-market repair shops advertise multi-point fluid "top-ups" in conjunction with oil changes or regular maintenance packages. These offers often include adding brake fluid to the master cylinder reservoir. There are only two reasons why the brake fluid level in the brake reservoir might go down. The first is that the brake fluid level goes down an acceptable level during normal brake lining wear. When the linings are replaced, the fluid will return to it's original level. The second possible reason for a low fluid level is that fluid is leaking out of the brake system. If fluid is leaking, the brake system requires repair and adding additional fluid will not correct the leak. If the system was properly filled during delivery of the vehicle, no additional fluid should be required under most circumstances between brake pad and/or shoe replacements. This information can be reinforced with the customer by referring them to the Brake Fluid section of their vehicle's Owner's Manual. Guidelines GM vehicles have incorporated a variety of brake fluid reservoir styles. The following guidelines are restricted to the plastic bodied fluid reservoirs and do not affect the original service recommendations for the older style metal bodied units. You may encounter both black plastic and translucent style reservoirs. You may have reservoirs with: ^ A MAX fill mark only ^ A MIN fill mark only ^ Both MAX and MIN marks The translucent style reservoirs do not have to have the covers removed in order to view the fluid level. It is a good practice not to remove the reservoir cover unless necessary to reduce the possibility of contaminating the system. Use the following guidelines to assist in determining the proper fluid level. Important: When adding brake fluid, use Delco Supreme II(R) Brake Fluid, GM P/N 12377967 or equivalent brand bearing the DOT-3 rating only. Important: At no time should the fluid level be allowed to remain in an overfilled condition. Overfilling the brake reservoir may put unnecessary stress on the seals and cover of the reservoir. Use the following guidelines to properly maintain the fluid level. If the reservoir is overfilled, siphon out the additional fluid to comply with the guidelines below. Important: If under any circumstance the brake fluid level is extremely low in the reservoir or the BRAKE warning indicator is illuminated, the brake system should be checked for leaks and the system repaired in addition to bringing the fluid level up to the recommended guidelines outlined below. A leaking brake system will have reduced braking performance and will eventually not work at all. Important: Some vehicles have reservoirs that are very sensitive to brake fluid levels and may cause the BRAKE indicator to flicker on turns as the fluid approaches the minimum required level. If you encounter a vehicle with this concern, increase the fluid level staying within the guidelines outlined below. ^ If the reservoir has a MAX level indicator, the reservoir should be returned to the MAX marking only at the time new brake pads and/or shoes are installed. If the reservoir fluid level is at the half-way point or above do not attempt to add additional brake fluid during routine fluid checks. ^ If the reservoir has both MAX and MIN indicators, the fluid level should be maintained above the MIN indicator during routine fluid checks and returned to the MAX indication only after new brake pads and/or shoes are installed. ^ For reservoirs with only a MIN indication, the fluid level should be maintained above the MIN indicator during routine fluid checks. Return the Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Brake Fluid - Level & Filling Recommendations > Page 3677 reservoir fluid level to full only after installing new brake pads and/or shoes. A full reservoir is indicated on translucent, snap cover reservoirs by a fluid level even with the top level of the view window imprinted into the side of the reservoir. On screw top models in black or translucent plastic, the full level is just below the bottom of the filler neck. Parts Information Part Number Description 12377967 Brake Fluid Parts are currently available from GMSPO. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations LH Front Of Dash. In LH Side Of Brake Fluid Reservoir Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch Brake Fluid Pressure Sensor/Switch: Description and Operation Brake Distribution Valve & Switch Fig. 16 Brake Distribution Switch. Normal Fig. 17 Brake Distribution Switch. Failed DESCRIPTION This switch assembly is used on some diagonally split brake systems and Corvette four wheel disc brake systems. It is connected to the outlet ports of the master cylinder and to the brake warning lamp and warns the driver if either the primary or secondary brake system has failed. OPERATION When hydraulic pressure is equal in both primary and secondary brake systems, the switch remains centered (figure 16). If pressure fails in one of the systems, the piston moves toward the inoperative side (figure 17). The shoulder of the piston contacts the switch terminal, providing a ground and lighting the warning lamp. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 3685 Brake Fluid Pressure Sensor/Switch: Description and Operation Brake Warning Lamp Switches Fig. 4 Pressure Differential Valve & Brake Warning Lamp Switch Fig. 5 Pressure Differential Valve & Brake Warning Lamp Switch Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 3686 Fig. 6 Pressure Differential Valve & Brake Warning Lamp Switch Fig. 7 Dual Master Cylinder With Built In Warning Lamp Switch There are four basic types of brake warning lamp switches as shown, Figs. 4 through 7. When a pressure differential occurs between the front and rear brake systems, the valves will shuttle toward the side with the low pressure. In the switch shown in Fig. 4, movement of the differential valve forces the switch plunger upward over the tapered shoulder of the valve to close the switch contacts and light the dual brake warning lamp, signaling a brake system failure. In Fig. 5, the valve assembly consists of two valves in a common bore that are spring loaded toward the centered position. The spring-loaded switch contact plunger rests on top of the valves in the centered position (right view). When a pressure differential occurs between the front and rear brake systems, the valves will shuttle toward the side with the low pressure. The spring-loaded switch plunger is ``triggered'' and the ground circuit for the warning lamp is completed, lighting the lamp (left view). In Fig. 6, as pressure falls in one system, the other system's normal pressure forces the piston to the inoperative side, contacting the switch terminal, causing the warning lamp on the instrument panel to glow. Fig. 7 shows the switch mounted directly in the master cylinder assembly. Whenever there is a specified differential pressure, the switch piston will activate the brake failure warning switch and cause the brake warning lamp to glow. Testing Warning Lamp Operation The warning lamp should illuminate when the ignition switch is in the start position, and turn off when the switch returns to run. If the brake lamp remains on after the ignition returns to run, check fluid level in master cylinder reservoir and inspect parking brake. If the warning lamp does not turn on during cranking, check for defective bulb or blown fuse. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 3687 Brake Fluid Pressure Sensor/Switch: Description and Operation Combination Valve Fig. 8 Combination Valve The combination valve, Fig. 8 is a metering valve, failure warning switch, and a proportioner in one assembly and is used on disc brake applications. The metering valve delays front disc braking until the rear drum brake shoes contact the drum. The failure warning switch is actuated in event of front or rear brake system failure, in turn activating a dash warning lamp. The proportioner balances front to rear braking action during rapid deceleration. Fig. 9 Metering Valve. Initial Braking Fig. 10 Metering Valve. Continued Braking Metering Valve When the brakes are not applied, the metering valve permits the brake fluid to flow through the valve, thus allowing the fluid to expand and contract with temperature changes. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 3688 When the brakes are initially applied, the metering valve stem moves to the left, preventing fluid to flow through the valve to the front disc brakes. This is accomplished by the smooth end of the metering valve stem contacting the metering valve seal lip at 4 to 30 psi, Fig. 9. The metering valve spring holds the retainer against the seal until a predetermined pressure is produced at the valve inlet port which overcomes the spring pressure and permits hydraulic pressure to actuate the front disc brakes, Fig. 10. The increased pressure into the valve is metered through the valve seal, to the front disc brakes, producing an increased force on the diaphragm. The diaphragm then pulls the pin, in turn pulling the retainer and reduces the spring pressure on the metering valve seal. Eventually, the pressure reaches a point at which the spring is pulled away by the diaphragm pin and retainer, leaving the metering valve unrestricted, permitting full pressure to pass through the metering valve. Fig. 11 Failure Warning Switch. Rear System Failure Failure Warning Switch If the rear brake system fails, the front system pressure forces the switch piston to the right, Fig. 11. The switch pin is then forced up into the switch, completing the electrical circuit and activates the dash warning lamp. When repairs are made and pressure returns to the system, the piston moves to the left, resetting the switch. The detent on the piston requires approximately 100 to 450 psi to permit full reset of the piston. In event of front brake system failure, the piston moves to the left and the same sequence of events is followed as for rear system failure except the piston resets to the right. Fluid Level Sensor This sensor mounted on the master cylinder will activate the Brake Warning lamp if a low brake fluid level is detected. The lamp will turn off once the fluid level is corrected. Fig. 12 Proportioner. Rapid Deceleration Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 3689 Fig. 13 Proportioner. Normal Braking Fig. 14 Proportioners Installed In Master Cylinder Proportioning or Pressure Control Valve During rapid deceleration, a portion of vehicle weight is transferred to the front wheels. This resultant loss of weight at rear wheels must be compensated for to avoid early rear wheel skid. The proportioner or pressure control valve reduces rear brake system pressure, delaying rear wheel skid. When the proportioner or pressure control valve is incorporated in the combination valve assembly, pressure developed within the valve acts against the large end of the piston, overcoming the spring pressure, moving the piston left, Fig. 12. The piston then contacts the stem seat and restricts line pressure through the valve. During normal braking operation, the proportioner or pressure control valve is not functional. Brake fluid flows into the proportioner or pressure control valve between the piston center hole and the valve stem, through the stop plate and to the rear brakes. Spring pressure loads the piston during normal braking, causing it to rest against the stop plate, Fig. 13. On diagonally split brake systems, two proportioners or pressure control valves are used. One controls the left rear brake, the other the right rear brake. The proportioners or pressure control valves are installed in the master cylinder rear brake outlet ports, Fig. 14. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 3690 Brake Fluid Pressure Sensor/Switch: Description and Operation Proportioning Valve Fig. 5 Gauge Hook-up For Testing Proportioning Valve (Typical) The proportioning valve (when used), Fig. 5, provides balanced braking action between front and rear brakes under a wide range of braking conditions. The valve regulates the hydraulic pressure applied to the rear wheel cylinders, thus limiting rear braking action when high pressures are required at the front brakes. In this manner, premature rear wheel skid is prevented. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Brake Hose To Caliper 32 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation Brake Proportioning/Combination Valve: Description and Operation Proportioner Valves DESCRIPTION The proportioner valve limits outlet pressure to the rear brakes after a predetermined master cylinder pressure has been reached. This is used when less rear apply force is needed to obtain optimum braking. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 3697 Brake Proportioning/Combination Valve: Testing and Inspection Fig. 5 Gauge Hook-up For Testing Proportioning Valve (Typical) When a premature rear wheel slide is obtained on a brake application, it usually is an indication that the fluid pressure to the rear wheels is above the 50% reduction ratio for the rear line pressure and that malfunction has occurred within the proportioning valve. To test the valve, install gauge set shown in Fig. 5 in brake line between master cylinder and proportioning valve, and at output end of proportioning valve and brake line as shown. Be sure all joints are fluid tight. Have a helper exert pressure on brake pedal (holding pressure). Obtain a reading on master cylinder output of approximately 700 psi. While pressure is being held as above, reading on valve outlet should be 550-610 psi. If the pressure readings do not meet these specifications, the valve should be removed and a new valve installed. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 3698 Brake Proportioning/Combination Valve: Service and Repair Compact Master Cylinder Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 3699 Proportioner Valves REMOVE OR DISCONNECT 1. Proportioner valve caps. NOTE: In order to remove the proportioner valve caps, it may be necessary to remove the master cylinder reservoir. 2. Proportioner valve cap "O" rings and discard. 3. Proportioner valve piston springs. 4. Proportioner valve pistons using needle nose pliers with care not to scratch or otherwise damage piston stems. 5. Proportioner valve seals from valve pistons. 6. Clean all parts in clean, denatured alcohol and dry with unlubricated compressed air. 7. Inspect proportioner valve pistons for corrosion, or deformation and replace if found. INSTALL OR CONNECT 1. Lubricate new proportioner valve cap "O" rings and proportioner valve seals with silicone grease supplied in repair kit. Also lubricate stem of proportioner valve pistons. 2. New proportioner valve seals on proportioner valve pistons with seal lips facing upward toward proportioner valve cap. 3. Proportioner valve pistons and seals in master cylinder body. 4. Proportioner valve piston springs in master cylinder body. 5. New proportioner valve cap "O" rings in grooves in proportioner valve caps. 6. Proportioner valve caps in master cylinder body and tighten to 27 Nm (20 lbs ft). 7. Master cylinder reservoir, if removed. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Master Cylinder To Booster 20 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 3703 Brake Master Cylinder: Description and Operation Compact Master Cylinder DESCRIPTION This master cylinder is a composite design for use in a diagonally split hydraulic system. It incorporates the functions of the standard dual master cylinder plus it has a fluid level sensor switch and integral proportioners. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 3704 Brake Master Cylinder: Testing and Inspection INSPECTION Inspect for Leakage NOTE: The master-cylinder should be cleaned thoroughly prior to inspection (several days preferably). Spilled brake fluid can be easily confused with leakage. Piston Seals Leakage around the piston seals will seep out from the end of the cylinder and leak down the outside of the brake booster. - Inspect for signs of seepage or bubbled paint on the brake booster. - If any leakage is detected the master-cylinder should be replaced or overhauled Brake Line Fittings While someone is applying pressure to the brake pedal, inspect the brake line fittings on the master-cylinder for leakage. - If the fittings are leaking they should be disassembled and inspected. Reservoir to Cylinder Gasket Inspect the gasket for signs of leakage or hardening and cracking. Overhaul or replace the master-cylinder if any leakage is indicated. Inspect for Oil Contamination. - Inspect the rubber gasket on the inside of the master-cylinder lid. If the gasket is swollen or bloated, the brake fluid is contaminated with oil. - Siphon or scoop a small amount of brake fluid out of the master-cylinder and place into a styrofoam cup filled 2/3 of the way with water. Brake fluid will mix with the water while oil contaminants will float on the surface and dissolve the styrofoam. NOTE: If any oil contamination is present ALL brake components containing rubber seals will need to be replaced or overhauled. This includes the master-cylinder, both front calipers, both rear wheel cylinders, and all flexible brake hoses. Verify Hold-Down Bolts Are Tight - While someone is applying and releasing pressure to the brake pedal, verify the the master-cylinder is tightly secured to the brake booster. Retighten hold-down bolts if necessary. Functional Checks WARNING: Always bleed the entire brake system and verify the rear brakes are properly adjusted prior to diagnosing a master-cylinder as defective. For additional information on master-cylinder / brake pedal relationship see Fundamentals and Basics. See: Fundamentals and Basics Check Related Systems Check for proper brake booster operation (NON-ABS ONLY) 1. With the engine "OFF", depress and release the brake pedal 4-5 times (this bleeds off the vacuum reserve in the booster). 2. Depress the brake pedal firmly and start the engine. If the pedal goes down slightly the brake booster is assisting in brake operation. If the pedal does not go down slightly the brake booster is not assisting in brake operation and should be diagnosed for problems. - Check and adjust rear brakes. - Check all brake lines and brake assemblies for leakage. Repair all deficiencies with related systems prior to diagnosing the master-cylinder as defective. Check Brake Pedal Travel (Non-Antilock Brake Systems Only) Fully depress the brake pedal and check for the following: The pedal should have a 75% reserve. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 3705 Pedal Reserve Checks - The pedal should be firm and not leak down. Prior to replacing a master-cylinder for poor pedal travel or feel verify the following: There were no problems with any of the related systems. - The entire brake system has been bled. - Rear brakes are properly adjusted. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Compact Master Cylinder Brake Master Cylinder: Service and Repair Compact Master Cylinder Removal For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics NOTE: If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. CAUTION: Brake fluid will damage painted surfaces. Brake fluid can also damage electrical connections. Shop cloths and clean containers should be used to prevent spillage of brake fluid. Fluid Level Sensor 1. Remove electrical connector from fluid level sensor (1). Removing Master Cylinder Assembly 2. Remove brake pipe tube nuts (22) from master cylinder assembly (21). 3. Plug open brake pipes to prevent brake fluid loss and contamination. 4. Remove master cylinder mounting nuts (20) to complete removal. Disassembly Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Compact Master Cylinder > Page 3708 Compact Master Cylinder Assembly 1. Remove master cylinder from vehicle. Refer to Brake Master Removal. See: 2. Remove reservoir cover (8) and diaphragm (9). Discard old brake fluid from reservoir. 3. Inspect cover (8) and diaphragm (9). Replace if cut, cracked or deformed. NOTE: Deformed and swollen rubber parts in a brake hydraulic system are indications of improper brake fluid, mineral oil or water contamination. Inspect all rubber parts and clean or replace as necessary. It is recommended that the complete hydraulic system be thoroughly flushed with clean brake fluid whenever new parts are installed. 4. Remove fluid level sensor (1) and proportioner valve assembly, if equipped (2 through 6). ^ In order to remove the proportioner valve caps (2), it may be necessary to remove the master cylinder reservoir (10). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Compact Master Cylinder > Page 3709 Removing And Installing Spring Pins Installing Reservoir MASTER CYLINDER RESERVOIR REMOVAL 1. Clamp flange on master cylinder body (20) in a vise. NOTE: Do not clamp on master cylinder body (11). Doing so may damage the master cylinder. 2. Remove spring pins (19) by using a suitable 1/8 inch punch to drive them out. ^ Use care not to damage reservoir (10) or cylinder body (11) when driving out spring pins (19). 3. Remove master cylinder reservoir (10) by pulling straight up, away from master cylinder body (11). Proportioner Valves 4. Remove reservoir to body "0" rings (7) from grooves in master cylinder reservoir (10) and dispose of "0" rings (7). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Compact Master Cylinder > Page 3710 PROPORTIONER VALVE REMOVAL 1. Remove proportioner valve caps (2). 2. Remove proportioner valve cap "0" rings (3) and discard. 3. Remove proportioner valve piston springs (4). 4. Remove proportioner valve pistons (5). ^ Use needle nose pliers with care not to scratch or otherwise damage piston stems. 5. Remove proportioner valve seals (6) from proportioner valve pistons (5). CLEAN ^ All parts in clean, denatured alcohol. ^ Dry with unlubricated compressed air. INSPECT ^ Proportioner valve pistons (5) for corrosion, or deformation and replace if found. DISASSEMBLY OF MASTER CYLINDER 1. Depress primary piston (17) while depressing piston retainer (18). ^ Take care not to damage the primary piston, master cylinder bore, or piston retainer groove. 2. Remove primary piston (17), secondary piston (15), secondary piston spring (12), and spring retainer (13). ^ To remove parts, apply low pressure unlubricated compressed air into upper outlet port at blind end of bore with all other outlet ports plugged. 3. Remove secondary seal (16), primary seal (14), and spring retainer (13) from secondary piston (15). CLEAN ^ All parts in clean, denatured alcohol. ^ Dry with unlubricated compressed air. ^ No abrasives should be used in bore. INSPECT ^ Master cylinder bore for scoring or corrosion. If noted, replace master cylinder. Assembly Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Compact Master Cylinder > Page 3711 Compact Master Cylinder Assembly ASSEMBLY NOTE: Lubricate all rubber parts with clean brake fluid prior to installation. 1. Install lubricated secondary seal (16), primary seal (14) and spring retainer (13) onto secondary piston (15). 2. Install secondary piston spring (12) and secondary piston assembly (13 through 16) into cylinder bore. 3. Install lubricated primary piston (17) into cylinder bore. 4. Install piston retainer (18) while depressing primary piston (17). 5. Install proportioner valve assemblies (2 through 6) and fluid level sensor (1). INSTALLATION OF PROPORTIONER VALVE Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Compact Master Cylinder > Page 3712 NOTE: Lubricate new proportioner valve cap "0" rings (3) and proportioner valve seals (6) with silicone grease supplied in repair kit. Also lubricate stem of proportioner valve pistons (5). 1. Install new proportioner valve seals (6) on proportioner valve pistons (5) with seal lips facing upward toward proportioner valve cap (2). 2. Install proportioner valve pistons (5) and seals (6) in master cylinder body (11). 3. Install proportioner valve piston springs (4) in master cylinder body (11). 4. Install new proportioner valve cap "0" rings (3) in grooves in proportioner valve caps (2). 5. Install proportioner valve caps (2) in master cylinder body (11). TIGHTEN ^ Proportioner valve caps (2) to 27 Nm (20 Ibs. ft.). INSTALLATION OF MASTER CYLINDER RESOVOIR ^ Clean reservoir with clean denatured alcohol and dry with unlubricated compressed air. INSPECT ^ Master cylinder reservoir (10) for cracks or deformation and replace reservoir (10) if damage is found. ASSEMBLE 1. Lubricate new reservoir to body "0" rings (7), and reservoir flanges with clean brake fluid. 2. Install reservoir to body "0" rings (7) into grooves in master cylinder reservoir (10). Be sure "0" rings are properly seated. 3. Install master cylinder reservoir (10) to master cylinder body (11) by pressing straight down by hand into master cylinder body (11). 4. Spring pins (19) by driving in with a one eighth inch punch using care not to damage resovoir or master cylinder body (11). 5. Install brake master onto vehicle. Refer to Installation. See: Installation For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics CAUTION: Brake fluid will damage painted surfaces. Shop cloths and clean containers should be used to prevent spillage of brake fluid. Removing Master Cylinder Assembly 1. Bench bleed master cylinder. 2. Install master cylinder assembly (21) to power booster assembly. 3. Tighten master cylinder assembly mounting nuts (20) to 27 Nm (20 lbs. ft.). 4. Tighten brake pipes tube nuts (22) to master cylinder assembly (21) to 20 Nm (11 lbs. ft.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Compact Master Cylinder > Page 3713 Brake Fluid Level Indicator 5. Install electrical connector to fluid level sensor (1). 6. Fill master cylinder to proper level with clean DOT 3 brake fluid. 7. Bleed hydraulic system. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Compact Master Cylinder > Page 3714 Brake Master Cylinder: Service and Repair Identifying Master Cylinder Types THERE ARE TWO DIFFERENT TYPES OF MASTER CYLINDERS AVAILABLE. Compact Master Cylinder Assembly Compact Master Cylinder This master cylinder is a composite design (plastic resovoir and aluminum body) and bolts onto the power booster. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Compact Master Cylinder > Page 3715 Master Cylinder Power Unit Assembly ABS Master Cylinder Power Unit Assembly A valve block and accumulator are attached to the master cylinder power unit assembly and bolts directly onto the firewall. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Page 3716 Brake Master Cylinder: Tools and Equipment BASIC SERVICE (Removal and Installation) - Fender cover (servicing and bleeding a master-cylinder can be a messy process) CAUTION: DOT 3 or 4 brake fluid is very corrosive to the vehicles finish and electrical connections. - Drip pan. - Complete set of combination wrenches or sockets. - Bleeding device: - Pressure bleeder or - Vacuum bleeder or - One-man brake bleeder kit or - Length of clear plastic hose (3/16 inch ID) and a glass jar. Brake Bleeding Setup - Small ruler or depth gauge (for adjusting the pushrod) - Brake adjusting tool (rear brake adjustment should be checked) - Clean shop towels. OPTIONAL - Master Cylinder bleeding kit (contains plastic fittings and hoses used for bleeding master cylinders) - Suction bulb (for removing brake fluid from reservoir) IF MASTER-CYLINDER IS OVERHAULED - Snap-ring pliers - Small pry bar (for separating the reservoir from the cylinder) - Cylinder hone (cast iron cylinders only) - Feeler gauges (for checking piston to cylinder clearance). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints Brake Master Cylinder: Fundamentals and Basics Notes, Warnings, and Hints REMOVAL WARNING: DOT 3 or DOT 4 brake fluid is very corrosive to your vehicles finish. Removing master cylinders can be a messy process. To prevent or minimize any possible damage perform the following: Siphon all brake fluid from the master-cylinder reservoir prior to removal. - Use a fender cover to protect the vehicles finish. - Use a drip pan to catch all fluid that leaks from the master-cylinder during removal. - Any brake fluid which contacts the vehicles finish should be washed off immediately. - Any brake fluid which drips onto electrical connections should be immediately removed (aerosol brake cleaner works well for this). After the brake lines have been disconnected from the master-cylinder place vacuum caps over ends of the lines to prevent further leakage or contamination. Once the master-cylinder has been removed place it in a drip pan. Although the reservoir is empty, brake fluid trapped within the cylinder bore will continue to slowly leak out. OVERHAUL WARNING: Never hone aluminum cylinders, if deposits cannot be removed with crocus cloth the cylinder should be replaced. Check the cylinder bore for excessive clearance. With the piston installed you should not be able to install a 0.006 inch feeler gauge between piston and cylinder. If the clearance is greater than 0.006 inches the cylinder should be replaced. When installing the piston and seals into the cylinder always use clean brake fluid or assembly lubricant to lubricate the components. INSTALLATION Prior to installation the master-cylinder should be bench bled (this can be done on the vehicle but it is much easier on a workbench. NOTE: Normal brake bleeding procedures will not remove air which is trapped in the cylinder bore area of a master-cylinder. Attach the brake line fittings prior to snugging down the master-cylinder retaining bolts. The fittings are much easier to start turning when the master-cylinder is still loose. WARNING: Remember to tighten the retaining bolts after the brake lines are installed and tightened. When snugging down the retaining bolts, alternately tighten them in small increments. This prevents the master-cylinder or push rod from becoming cocked. Upon installing the master-cylinder the entire brake system (front and rear) will need to be bled. Air enters the brake system as soon as the brake lines are removed. It only requires a very small amount of air in the system to create a soft brake pedal. WARNING: Never test drive a vehicle after a master-cylinder replacement until a firm brake pedal with a 75% reserve is established. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3719 Brake Master Cylinder: Fundamentals and Basics Parts Reminder List RECOMMENDED PARTS Basic Service, Replacement New or rebuilt master-cylinder - Fresh/New brake fluid If Overhaul is Required Master cylinder overhaul kit - Brake assembly lubricant Optional Aerosol brake cleaner. New or Rebuilt Master Cylinder Always closely compare the new master-cylinder with the old master-cylinder. Minor variations in the size and depth of the primary piston can result in significant reductions in braking performance. Examine the end of the master-cylinder where the pushrod contacts the piston. The depth and diameters of the pistons should match. Brake Fluid Proper bench bleeding the master-cylinder and flushing the brake system will require a minimum of 16 oz of brake fluid. - Never Mix DOT 3 (light amber in color) with DOT 5 (purple in color). There have been reports of damage to brake system seals when DOT 3 and DOT 5 fluids are mixed - Always store brake fluid in a sealed container. When left open brake fluid will absorb moisture from the air. This reduces the boiling point of the brake fluid and could lead to a soft pedal or brake system failure during prolonged or emergency braking. - Never add automatic transmission fluid, engine oil, or power steering fluid to the master-cylinder. Petroleum based fluids will cause the rubber seals and gaskets in the brake system to swell and leak. Master Cylinder Overhaul Kit Overhaul kits will often come with a variety cup and seal sizes. Closely match the old cups and seals with the new ones. Brake Assembly Lubricant Assembly lubricant can greatly simply the master-cylinder overhaul process and prolong the life of the new seals. - Clean brake fluid can be used to lubricate the master-cylinder bore during assembly but assembly lube is much slicker and prevents any sticking or binding and possible damage to the new cups and seals. Aerosol Brake Cleaner - Commercially produced aerosol brake cleaners are designed to effectively clean brake systems while not leaving an oily residue. - Do not use carburetor cleaner or solvent based products to clean brake system components. These products will leave a residue which could contaminate the brake fluid or cause a reduction in braking performance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3720 Brake Master Cylinder: Fundamentals and Basics Master Cylinder / Brake Pedal Relationship MASTER CYLINDER / BRAKE PEDAL RELATIONSHIP WARNING: Master Cylinders can be easily misdiagnosed for problems related to excessive brake pedal travel. Excessive brake pedal travel is often associated with a defective master-cylinder, however total pedal travel is affected by a wide variety of components and issues. Issues Affecting Pedal Travel Brake Fluid Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3721 - Brake fluid which is contaminated with air or water will significantly add to the amount of pedal travel. - Pure DOT 3 (or 4) brake fluid is incompressible (allowing for a solid, firm pedal). A small amount of air trapped in the brake fluid will require extra effort from the master-cylinder to compress it, resulting in a soft and spongy pedal. - During prolonged or severe braking the brake fluid temperature can rapidly rise above 212 degrees F. When this occurs any water in the brake fluid will boil into steam (which is compressable) and create a soft and spongy pedal. Rear Brake Shoe Adjustment Drum brake system utilize return springs to pull the shoes away from the drums when not in use. The amount of distance the shoes have to extend to meet the drums greatly affects the amount of pedal travel. - Shoes/Linings which are badly out of adjustment can by themselves result in a brake pedal sinking all the way to the floor NOTE: Improperly adjusted rear shoes/linings also affect the parking brake. Calipers Excessive rotor wobble caused by a warped rotor or loose/worn wheel bearings can knock the caliper piston further inward from its normal resting position. This results in additional pedal travel required to extend the piston and apply the brakes. Drum Expansion Drums which are worn past their "Discard" thickness are prone to expanding outwards into an oval shape during heavy braking. This drum expansion results in additional brake pedal travel. Brake Fade During prolonged or severe braking, the amount of pedal effort/travel required to slow the vehicle increases as the ability of the brakes to dissipate heat decreases. - As the brake linings heat up, their "coefficient of friction" is reduced (they become slicker). As the coefficient of friction is reduced, more hydraulic pressure is required to stop the vehicle. More hydraulic pressure results in more heat which then results in more pedal fade. - As the brake linings, rotors, and drums begin to wear, their ability to absorb and release heat is reduced significantly. This makes worn brakes more prone to "pedal fade". NOTE: Prior to replacing a master-cylinder, verify the entire brake system is functioning properly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3722 Brake Master Cylinder: Fundamentals and Basics Bench Bleeding BENCH BLEEDING Why A master-cylinder will develop little or no pressure if air is trapped in cylinder bore. Normal brake bleeding will not remove air trapped within the master-cylinder. How Clamp the master-cylinder securely in a vice. It is usually best to clamp the side of the vice onto the flat surface that is used to secure the master-cylinder to the brake booster. There are two basic methods for bleeding master-cylinder, one utilizes stroking the master-cylinder to expel air from the cylinder bore while the other utilizes a large syringe to backflush fluid from the outlet ports to the reservoir. Stroking Fill the master-cylinder with clean brake fluid. - The brake line fittings on the master-cylinder should be capped or plugged. NOTE: Special "bench bleeding" plastic fittings are available which allow for recirculating the brake fluid back into the reservoir. - Using a dull object, slowly stroke the master-cylinder piston, air and brake fluid will be expelled from the brake line fittings. Prior to releasing the piston plug or cap the outlet ports. - Repeat this procedure 8-10 times or until no air is emitted from the outlet ports. - When finished, cap the outlet ports and install the master-cylinder. Syringe Fill the syringe (one especially designed for brake bleeding) with clean brake fluid. - Insert the end of the syringe into one of the outlet ports on the master-cylinder. - Slowly compress the syringe and back flush the brake fluid through the master-cylinder. - A combination of air and brake fluid will be emitted from the inlet port in the fluid reservoir. - Repeat this procedure until only brake fluid is emitted into the reservoir. - Cap the outlet ports and install the master-cylinder. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder To Backing Plate 15 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal Wheel Cylinder: Service and Repair Removal For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Wheel Cylinder 1. Raise vehicle and support on jack stands. 2. Mark relationship of wheel to axle flange, then remove wheel and tire assembly. 3. Mark relationship of brake drum to axle flange. 4. Remove brake drum. 5. Remove dirt and foreign material around wheel cylinder assembly inlet and pilot. CAUTION: Do not pull metal line away from cylinder, as this may kink or bend line. Line will separate from cylinder when cylinder is moved away from brake backing plate. 6. Disconnect hydraulic line at wheel cylinder. 7. Plug opening in line to prevent fluid loss and contamination. 8. Remove wheel cylinder bolts (21) using a #6 Torx socket. 9. Remove wheel cylinder. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 3728 Wheel Cylinder: Service and Repair Overhaul For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Wheel Cylinder Wheel Cylinder Components 1. Remove boots (22), pistons (23) and seals (24), spring assembly (25) and bleeder valve (20). 2. Clean all parts with brake fluid. 3. Inspect cylinder bore and pistons for scoring, nicks, corrosion and wear. Use crocus cloth to polish out light corrosion. ^ Replace wheel cylinder assembly if bore will not clean up with crocus cloth. ASSEMBLY NOTE: Ensure hands are clean before proceeding with assembly. 1. Clean all parts in clean denatured alcohol. 2. Dry parts with unlubricated compressed air. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 3729 3. Lubricate cylinder wall and rubber cups with clean brake fluid, then install spring assembly (25), seals (24), pistons (23) and boots (22). 4. Wipe end of hydraulic line to remove any foreign matter, then place wheel cylinder in position. Enter tubing into cylinder and start threads on fitting. 5. Secure cylinder to backing plate, then complete tightening of tubing fitting. Torque to 17 Nm (12 lbs. ft.). 6. Install bleeder valve (20). Torque to 7 Nm (65 lbs. in.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 3730 Wheel Cylinder: Service and Repair Installation For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Wheel Cylinder 1. Position wheel cylinder assembly (28) and hold in place with wooden block between cylinder and axle flange. 2. Install wheel cylinder bolts (21) using a #6 Torx socket. ^ Torque wheel cylinder bolts to 20 Nm (15 lbs. ft.). 3. Install inlet tube line and nut. ^ Torque inlet tube nut to 17 Nm (12 lbs. ft.). 4. Bleed the brake system. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Page 3731 Wheel Cylinder: Fundamentals and Basics REMOVAL - Wheel cylinder retaining bolts, brake line fittings, and bleeder screws are often heavily corroded. Prior to starting the job you should spray these with a penetrating oil. - A line (flare nut) wrench should be used when loosening the brake line fittings. These fittings round off easily. OVERHAUL - Light amounts of corrosion within the cylinder bore and on the piston may be removed with crocus cloth. - Pitting and heavy corrosion should be removed with a hone. When honing the hone should be inserted and withdrawn quickly to achieve a 45 degree crosshatch. - Closely inspect the areas of the cylinder where the pistons seals contact. It is very important these areas are absolutely free of deposits, corrosion, or pitting. - Remove the bleeder screw and verify that the passage is clear. - Leave the bleeder open when installing pistons and cups into the cylinder bore. If the bleeder is closed a large amount of air will be forced into the brake lines. - Use brake assembly lubricant to coat the cylinder bore, pistons, and cups. Clean brake fluid is an acceptable lubricant when assemblying the wheel-cylinder but brake assembly lubricant is much slicker and minimizes the chance that the cups will be damaged. WARNING: Do not use a petroleum based grease or oil to lubricate the wheel-cylinder components. This will cause the seals and cups to swell and deteriorate. - When reassemblying the wheel-cylinder it is helpful to follow this sequence: 1. Rear cup (verify the cup is inserted properly, flat side towards the piston, concave side towards the center) 2. Rear piston 3. Rear dust cap (this prevents the rear cup and piston from popping back out when the spring and front components are installed). 4. Spring 5. Front cup 6. Front piston 7. Front dust cap INSTALLATION Attach the brake fluid line fitting loosely to the wheel-cylinder prior to inserting and tightening the retaining bolts. The brake fluid line fitting is much easier to attach and start turning with the wheel-cylinder loose. WARNING: Don't forget to tighten the brake line fitting after the retaining bolts are tightened. - Leave the wheel-cylinder bleeder screw open and place a drip pan under the rear brake assembly. Refill the master-cylinder with new brake fluid and let the fluid gravity bleed through the open bleeder screw. When brake fluid begins to drip from the bleeder, close the bleeder screw. NOTE: The brake system will still need to be flushed and bled, but this makes starting the process much easier. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Testing and Inspection Parking Brake Cable: Testing and Inspection Inspect parking brake cable end for kinks, fraying and elongation and replace as necessary. Use a small hose clamp to compress clamp where it enters backing plate to remove. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Technical Service Bulletins > Console - Park Brake Lever Brushes Loose Parking Brake Lever: Technical Service Bulletins Console - Park Brake Lever Brushes Loose Number: 92-251-5 Section: 5 Date: AUGUST 1992 Corporate Bulletin No.: 238302 ASE No.: A5 Subject: CONSOLE PARK BRAKE LEVER BRUSH LOOSE Model and Year: 1991-92 CAVALIER Condition: Examination of returned parts on some Chevrolet Cavalier cars have revealed that replacement has been due to park brake brushes that become loose. Affected consoles can be repaired instead of replaced. Correction: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Technical Service Bulletins > Console - Park Brake Lever Brushes Loose > Page 3740 Remove console assembly, following the appropriate 1991 and 1992 "J" Car Service Manual procedure in Section 8C. Apply adhesive P/N 12345632, or equivalent, as shown and hold in place for approximately one minute. Parts are currently available from GMSPO. Labor Operation Number C-2860 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations Parking Brake Release Switch: Locations In Console, At Base Of Parking Brake Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation Vacuum Brake Booster: Description and Operation Two basic types of power assist mechanisms are used: vacuum assist diaphragm assemblies, which use engine vacuum or, in some cases vacuum pressure developed by an external vacuum pump. The second type is a hydraulic pressure assist mechanism, which use pressure developed by an external pump (usually the power steering pump). Both systems act to increase the force exerted on the master cylinder piston by the operator. This in turn increases the hydraulic pressure delivered to the wheel cylinders, while decreasing driver effort necessary to obtain acceptable stopping performance. Vacuum assist units are similar in operation and get their energy by opposing engine vacuum to atmospheric pressure. A piston and cylinder, flexible diaphragm (bellows) utilize this energy to provide brake assistance. The fundamental difference between these types of vacuum assist systems lies simply in how the diaphragm within the power unit is suspended when the brakes are not applied. In order to properly diagnose vacuum assist system malfunctions it is important to know whether the diaphragm within a power unit is air suspended or vacuum suspended. Air-suspended units are under atmospheric pressure until the brakes are applied. Engine vacuum is then admitted, causing the piston or diaphragm to move (or the bellows to collapse). Vacuum-suspended types are balanced with engine vacuum until the brake pedal is depressed, allowing atmospheric pressure to unbalance the unit and apply force to the brake system. Regardless of whether the brakes are vacuum or hydraulically assisted, certain general service procedures apply. Only specified, clean brake fluid should be used in brake system. On hydro boost systems, use of the specified hydraulic fluid in the boost circuit is essential to proper system operation. Care must be taken not to mix the fluids of the two separate operating circuits. Use of improper fluids, or contaminated fluid will cause damage to the seals and valves. DELCO-MORAINE TANDEM DIAPHRAGM TYPE Fig. 10 Delco-Moraine Tandem Diaphragm Booster Exploded View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 3748 Fig. 11 Power Head Assembly Exploded View. Delco-Moraine Tandem Diaphragm Booster This unit utilizes a vacuum power chamber, consisting of a front and rear shell, housing divider, front and rear diaphragm, plate assemblies, hydraulic pushrod and a diaphragm return spring, Figs. 10 and 11. The unit operates in much the same manner as the single diaphragm unit described previously. The diaphragm and plate assemblies utilize the pressure differential between the engine intake manifold vacuum and atmospheric pressure to assist in braking. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 3749 Vacuum Brake Booster: Service and Repair Fig. 10 Delco-Moraine Tandem Diaphragm Booster Exploded View Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 3750 Fig. 11 Power Head Assembly Exploded View. Delco-Moraine Tandem Diaphragm Booster Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 3751 Fig. 12 Girlock Brake Booster Exploded View Disassembly 1. Remove pedal pushrod boot, silencer, check valve, vacuum switch and grommets, as equipped, then the front housing seal. 2. Scribe matching marks between front and rear housing sections, then mount booster assembly in suitable holding fixture with rear housing facing up. 3. Apply pressure to housing with holding fixture forcing screw and rotate rear housing counterclockwise to unlock housing halves. 4. Slowly release spring tension, then remove booster assembly from holding fixture. Do not allow spring tension to release suddenly, as damage or personal injury may result. 5. Lift off rear housing, then remove primary power piston bearing from housing. 6. Remove power piston group and return spring from front housing, Fig. 10. 7. Remove master cylinder piston rod and reaction retainer from front of piston, then the silencer from the rear of the assembly, Fig. 11. 8. Hold piston assembly at edges of divider and strike pedal pushrod against work surface to dislodge diaphragm retainer. 9. Remove primary diaphragm and support plate, secondary power piston bearing and housing divider, then the secondary diaphragm and support plate from piston, noting installation position of components, Fig. 12. 10. Clean and inspect components, then replace as needed. Do not disassemble power piston. If service is required, power piston must be replaced as an assembly. Assembly 1. Position power piston assembly on work surface with pedal pushrod facing up. 2. Lubricate inner lip of secondary diaphragm, fit diaphragm over support plate, then install assembly onto power piston. 3. Install secondary power piston bearing into divider with flat surface of bearing on side of divider with 6 lugs, Fig. 11. 4. Install guide sleeve J-28458 or equivalent over power piston, lubricate inner diameter of secondary bearing, then install divider assembly with lugged side facing up. 5. Lubricate inner lip of primary diaphragm. Fit diaphragm over support plate, then install diaphragm assembly on power piston. 6. Ensure diaphragms and support plates are properly positioned, install new diaphragm retainer, then seat retainer on power piston using guide sleeve J-28458 or equivalent and hammer. 7. Install primary power piston bearing in rear housing, then lubricate inner diameter of bearing. 8. Mount front housing in holding fixture J-23456 or equivalent, then install diaphragm return spring, power piston group and the rear housing Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 3752 assembly, Fig. 10. 9. Ensure housing scribe marks are properly aligned, then press housing sections together with holding fixture forcing screw. Assembly of housing can be facilitated by applying vacuum to front housing port. Block opening for vacuum switch, if equipped. 10. Rotate rear housing clockwise to lock housing, then stake two tabs 180° apart to secure assembly. Do not stake tabs which have previously been used. 11. Lubricate grommets and front seal, install grommets, check valve and vacuum switch, as equipped, then the front housing seal. 12. Install silencer and pedal pushrod boot. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations LH Front Of Dash. In LH Side Of Brake Fluid Reservoir Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch Brake Fluid Pressure Sensor/Switch: Description and Operation Brake Distribution Valve & Switch Fig. 16 Brake Distribution Switch. Normal Fig. 17 Brake Distribution Switch. Failed DESCRIPTION This switch assembly is used on some diagonally split brake systems and Corvette four wheel disc brake systems. It is connected to the outlet ports of the master cylinder and to the brake warning lamp and warns the driver if either the primary or secondary brake system has failed. OPERATION When hydraulic pressure is equal in both primary and secondary brake systems, the switch remains centered (figure 16). If pressure fails in one of the systems, the piston moves toward the inoperative side (figure 17). The shoulder of the piston contacts the switch terminal, providing a ground and lighting the warning lamp. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 3761 Brake Fluid Pressure Sensor/Switch: Description and Operation Brake Warning Lamp Switches Fig. 4 Pressure Differential Valve & Brake Warning Lamp Switch Fig. 5 Pressure Differential Valve & Brake Warning Lamp Switch Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 3762 Fig. 6 Pressure Differential Valve & Brake Warning Lamp Switch Fig. 7 Dual Master Cylinder With Built In Warning Lamp Switch There are four basic types of brake warning lamp switches as shown, Figs. 4 through 7. When a pressure differential occurs between the front and rear brake systems, the valves will shuttle toward the side with the low pressure. In the switch shown in Fig. 4, movement of the differential valve forces the switch plunger upward over the tapered shoulder of the valve to close the switch contacts and light the dual brake warning lamp, signaling a brake system failure. In Fig. 5, the valve assembly consists of two valves in a common bore that are spring loaded toward the centered position. The spring-loaded switch contact plunger rests on top of the valves in the centered position (right view). When a pressure differential occurs between the front and rear brake systems, the valves will shuttle toward the side with the low pressure. The spring-loaded switch plunger is ``triggered'' and the ground circuit for the warning lamp is completed, lighting the lamp (left view). In Fig. 6, as pressure falls in one system, the other system's normal pressure forces the piston to the inoperative side, contacting the switch terminal, causing the warning lamp on the instrument panel to glow. Fig. 7 shows the switch mounted directly in the master cylinder assembly. Whenever there is a specified differential pressure, the switch piston will activate the brake failure warning switch and cause the brake warning lamp to glow. Testing Warning Lamp Operation The warning lamp should illuminate when the ignition switch is in the start position, and turn off when the switch returns to run. If the brake lamp remains on after the ignition returns to run, check fluid level in master cylinder reservoir and inspect parking brake. If the warning lamp does not turn on during cranking, check for defective bulb or blown fuse. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 3763 Brake Fluid Pressure Sensor/Switch: Description and Operation Combination Valve Fig. 8 Combination Valve The combination valve, Fig. 8 is a metering valve, failure warning switch, and a proportioner in one assembly and is used on disc brake applications. The metering valve delays front disc braking until the rear drum brake shoes contact the drum. The failure warning switch is actuated in event of front or rear brake system failure, in turn activating a dash warning lamp. The proportioner balances front to rear braking action during rapid deceleration. Fig. 9 Metering Valve. Initial Braking Fig. 10 Metering Valve. Continued Braking Metering Valve When the brakes are not applied, the metering valve permits the brake fluid to flow through the valve, thus allowing the fluid to expand and contract with temperature changes. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 3764 When the brakes are initially applied, the metering valve stem moves to the left, preventing fluid to flow through the valve to the front disc brakes. This is accomplished by the smooth end of the metering valve stem contacting the metering valve seal lip at 4 to 30 psi, Fig. 9. The metering valve spring holds the retainer against the seal until a predetermined pressure is produced at the valve inlet port which overcomes the spring pressure and permits hydraulic pressure to actuate the front disc brakes, Fig. 10. The increased pressure into the valve is metered through the valve seal, to the front disc brakes, producing an increased force on the diaphragm. The diaphragm then pulls the pin, in turn pulling the retainer and reduces the spring pressure on the metering valve seal. Eventually, the pressure reaches a point at which the spring is pulled away by the diaphragm pin and retainer, leaving the metering valve unrestricted, permitting full pressure to pass through the metering valve. Fig. 11 Failure Warning Switch. Rear System Failure Failure Warning Switch If the rear brake system fails, the front system pressure forces the switch piston to the right, Fig. 11. The switch pin is then forced up into the switch, completing the electrical circuit and activates the dash warning lamp. When repairs are made and pressure returns to the system, the piston moves to the left, resetting the switch. The detent on the piston requires approximately 100 to 450 psi to permit full reset of the piston. In event of front brake system failure, the piston moves to the left and the same sequence of events is followed as for rear system failure except the piston resets to the right. Fluid Level Sensor This sensor mounted on the master cylinder will activate the Brake Warning lamp if a low brake fluid level is detected. The lamp will turn off once the fluid level is corrected. Fig. 12 Proportioner. Rapid Deceleration Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 3765 Fig. 13 Proportioner. Normal Braking Fig. 14 Proportioners Installed In Master Cylinder Proportioning or Pressure Control Valve During rapid deceleration, a portion of vehicle weight is transferred to the front wheels. This resultant loss of weight at rear wheels must be compensated for to avoid early rear wheel skid. The proportioner or pressure control valve reduces rear brake system pressure, delaying rear wheel skid. When the proportioner or pressure control valve is incorporated in the combination valve assembly, pressure developed within the valve acts against the large end of the piston, overcoming the spring pressure, moving the piston left, Fig. 12. The piston then contacts the stem seat and restricts line pressure through the valve. During normal braking operation, the proportioner or pressure control valve is not functional. Brake fluid flows into the proportioner or pressure control valve between the piston center hole and the valve stem, through the stop plate and to the rear brakes. Spring pressure loads the piston during normal braking, causing it to rest against the stop plate, Fig. 13. On diagonally split brake systems, two proportioners or pressure control valves are used. One controls the left rear brake, the other the right rear brake. The proportioners or pressure control valves are installed in the master cylinder rear brake outlet ports, Fig. 14. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation > Brake Distribution Valve & Switch > Page 3766 Brake Fluid Pressure Sensor/Switch: Description and Operation Proportioning Valve Fig. 5 Gauge Hook-up For Testing Proportioning Valve (Typical) The proportioning valve (when used), Fig. 5, provides balanced braking action between front and rear brakes under a wide range of braking conditions. The valve regulates the hydraulic pressure applied to the rear wheel cylinders, thus limiting rear braking action when high pressures are required at the front brakes. In this manner, premature rear wheel skid is prevented. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations Parking Brake Release Switch: Locations In Console, At Base Of Parking Brake Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Start Switch <--> [Clutch Switch] > Component Information > Locations Clutch Start Switch: Locations Below LH Side Of I/P. Behind I/P, On Clutch Pedal Support Applicable to: 1991 Cavalier w/Manual Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Start Switch <--> [Clutch Switch] > Component Information > Locations > Page 3775 Clutch Start Switch: Service and Repair 1. Disconnect clutch switch electrical connector. 2. Remove clutch bracket and switch attaching nuts, then remove switch. 3. Reverse procedure to install. Torque switch attaching nuts to 53 inch lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking Ignition Switch Lock Cylinder: Customer Interest Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3785 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3786 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3787 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3788 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3789 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3790 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 931943F > May > 93 > Ignition Lock Cylinder - Replacement Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Replacement Number: 93-194-3F Section: 3F Date: MAY 1993 Corporate Bulletin No.: 333207 ASE No.: A4 Subject: IGNITION LOCK CYLINDER REPLACEMENT Model and Year: 1991-93 CAVALIER SERVICE UPDATE When drilling out the ignition lock cylinder housing assembly shear bolts, care must be taken to remove the steering column from the car. Both the wiper switch and the turn signal switch must be removed before drilling the bolts out. There is a concern that metal shavings from the drilling of ignition lock cylinder shear bolts may enter the switches and cause the switch to become inoperative. The revised procedure below should be used. REMOVE 1. Steering wheel and covers (see Section 3F). 2. Steering column from vehicle (see Section 3F). 3. Turn signal switch from steering column (see Section 3F). 4. Wash/wipe switch from steering column (see Section 3F). IMPORTANT: Both the turn signal switch and wash/wipe switch have to be removed to prevent any metal shavings from entering the electrical components. 5. Lock cylinder housing assembly as follows: Put key in run position. - Drill off heads of two shear bolts using a 6.5 mm (1/4") drill bit. - Remove lock cylinder housing assembly. - Remove threaded ends of shear bolts from lock cylinder housing assembly with locking type pliers. - Clean all metal shavings from all parts after drilling. INSTALL 1. Lock cylinder housing assembly with two shear bolts. Key in run position. 2. Tighten two shear bolts until bolt head separates from bolt body approximately 11.0 N-m (97 lbs.in.) 3. Wash/wipe switch onto steering column (see Section 3F). 4. Turn signal switch onto steering column (see Section 3F). 5. Steering column into vehicle (see Section 3F). 6. Steering wheel and covers (see Section 3F). NOTE: Because the correct procedure must be followed when replacing ignition lock cylinders, Warranty will not be paid on turn signal or wiper/wash switches for 30 days after an ignition lock cylinder replacement. Use current labor time. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3800 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3801 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3802 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3803 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3804 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3805 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 931943F > May > 93 > Ignition Lock Cylinder - Replacement Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Replacement Number: 93-194-3F Section: 3F Date: MAY 1993 Corporate Bulletin No.: 333207 ASE No.: A4 Subject: IGNITION LOCK CYLINDER REPLACEMENT Model and Year: 1991-93 CAVALIER SERVICE UPDATE When drilling out the ignition lock cylinder housing assembly shear bolts, care must be taken to remove the steering column from the car. Both the wiper switch and the turn signal switch must be removed before drilling the bolts out. There is a concern that metal shavings from the drilling of ignition lock cylinder shear bolts may enter the switches and cause the switch to become inoperative. The revised procedure below should be used. REMOVE 1. Steering wheel and covers (see Section 3F). 2. Steering column from vehicle (see Section 3F). 3. Turn signal switch from steering column (see Section 3F). 4. Wash/wipe switch from steering column (see Section 3F). IMPORTANT: Both the turn signal switch and wash/wipe switch have to be removed to prevent any metal shavings from entering the electrical components. 5. Lock cylinder housing assembly as follows: Put key in run position. - Drill off heads of two shear bolts using a 6.5 mm (1/4") drill bit. - Remove lock cylinder housing assembly. - Remove threaded ends of shear bolts from lock cylinder housing assembly with locking type pliers. - Clean all metal shavings from all parts after drilling. INSTALL 1. Lock cylinder housing assembly with two shear bolts. Key in run position. 2. Tighten two shear bolts until bolt head separates from bolt body approximately 11.0 N-m (97 lbs.in.) 3. Wash/wipe switch onto steering column (see Section 3F). 4. Turn signal switch onto steering column (see Section 3F). 5. Steering column into vehicle (see Section 3F). 6. Steering wheel and covers (see Section 3F). NOTE: Because the correct procedure must be followed when replacing ignition lock cylinders, Warranty will not be paid on turn signal or wiper/wash switches for 30 days after an ignition lock cylinder replacement. Use current labor time. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Neutral Start Switch 20 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3817 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3818 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3819 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3820 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3821 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3822 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3823 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3824 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3825 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3826 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3827 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3828 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3829 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3830 Neutral Safety Switch: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3831 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3832 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3833 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3834 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3835 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 3836 Neutral Safety Switch: Service and Repair Disable the Supplemental Inflatable Restraint (SIR) system as described in BODY ELECTRICAL SAFETY AND ENTERTAINMENT/PASSIVE RESTRAINTS, AIR BAG/MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING prior to working on or near the steering column. 1. Disconnect battery ground cable. 2. Disconnect shift cable from transaxle. 3. Disconnect electrical connector from switch. 4. Remove two switch mounting bolts and the switch. 5. Align flats on switch with flats on transaxle shaft and push switch over shaft and fully seat on transaxle. 6. Install and torque switch mounting bolts to 20 ft. lbs. If switch was rotated and the pin broken, the switch will be automatically reset to the neutral position as follows: a. Place transaxle shaft in neutral position. b. Install switch on transaxle as outlined previously and loosely install mounting bolts. c. Insert a 3/32 inch gauge pin into service adjustment hole of switch. d. Rotate switch until pin drops in detent. e. Torque mounting bolts to 20 ft. lbs. f. Rearm airbag system as described under BODY ELECTRICAL SAFETY AND ENTERTAINMENT/PASSIVE RESTRAINTS, AIR BAG/MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions Battery Cable: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3842 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3843 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3844 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3845 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3846 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3847 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3848 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3849 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3850 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3851 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3852 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3853 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3854 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3855 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3856 Battery Cable: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3857 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3858 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3859 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3860 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Diagrams > Diagram Information and Instructions > Page 3861 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Tools - Released for CS Generator Diagnosis Alternator: Technical Service Bulletins Tools - Released for CS Generator Diagnosis File In Section: 6 - Engine Bulletin No.: 83-64-09 Date: March, 1998 INFORMATION Subject: New Tool J 41450-B, Released for CS Generator Diagnosis Models: 1988-98 Passenger Cars and Light Trucks with CS-Series Generators A new CS-Series Generator Tester, J 41450-B, has been sent to all dealers as part of the Essential Tool Package. This tool will work on all CS-Series generators for past model years. The tool is shown in Figure 1. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Tools - Released for CS Generator Diagnosis > Page 3867 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Tools - Released for CS Generator Diagnosis > Page 3868 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Tools - Released for CS Generator Diagnosis > Page 3869 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Tools - Released for CS Generator Diagnosis > Page 3870 Generator Not Operating Properly The charts shown can be used in place of the diagnostic procedures in previous Service Manuals when this new tool is used. This information will be included in the 1999 Service Manual. Inspect the following before testing the generator: ^ The battery. Make sure the vehicle battery is in good condition and fully charged. Refer to Battery Load Test. ^ The built in hydrometer in the battery. The green eye must be showing in the hydrometer. ^ The voltage across the battery terminals with all the loads OFF should be above 12 V. Refer to Battery Load Test. ^ Make sure the battery connections are clean and tight. ^ The drive belt for damage or looseness. ^ The wiring harness at the generator. Make sure the harness connector is tight and latched. Make sure the output terminal of the generator is connected to the vehicle battery (positive) generator lead. ^ All the charging system related fuses and electrical connections for damage or looseness. Refer to the starter and charging system schematics. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3873 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3874 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3875 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3876 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3877 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3878 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3879 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3880 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3881 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3882 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3883 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3884 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3885 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3886 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3887 Alternator: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3888 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3889 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3890 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3891 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3892 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 3893 Alternator Specifications Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 3894 Alternator: Description and Operation Fig. 1 Nippondenso Alternator This alternator has an IC integral solid state regulator. Fig. 1. All regulator components are enclosed into a solid mold and are attached to the slip ring end frame along with the brush holder assembly. The alternator voltage setting cannot be adjusted. The alternator rotor bearing contain enough grease to eliminate the need for periodic lubrication. Two brushes carry current through the two slip rings to the field coil mounted on the rotor. The stator windings are assembled on the inside of a laminated core that form part of the alternator frame. The rectifier bridge contains six diodes which electrically change stator A.C. voltage into D.C. voltage. The neutral diodes serve to convert the voltage fluctuation at the neutral point to direct current for increasing generator output. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Alternator: Initial Inspection and Diagnostic Overview Do not attempt to disassemble a CS-121 or CS-130 series generator. Damage to the generator assembly could result. The CS-121 or CS-130 series generators are not repairable and must be replaced as an assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3897 Alternator: Diagnostic Trouble Code Tests and Associated Procedures Fig. 2 CS Charging System Wiring Diagram DIAGNOSIS During normal system operation, the indicator lamp, if equipped, will illuminate until the engine is started. If the indicator lamp operates abnormally, or an overcharged or undercharged battery condition exists, the following procedure should be used to diagnose the charging system. Refer to charging circuit wiring diagram, Fig. 1, when diagnosing the system. 1. Ensure alternator drive belt is tight and in good condition. 2. On models equipped with a charge indicator lamp, proceed as follows: a. Observe indicator lamp with ignition on and engine not running. b. If lamp does not light, disconnect electrical connector from alternator and ground L terminal. c. If lamp lights, replace alternator assembly. If lamp does not light, locate and repair open circuit between ground and ignition switch. d. Observe indicator lamp with engine running at idle. e. If lamp lights, disconnect electrical connector from alternator and observe lamp. f. If lamp goes out, replace alternator assembly. If lamp remains lit, locate and repair ground in L terminal wire. 3. On all models, if battery is overcharged or undercharged, proceed as follows: a. Disconnect electrical connector from alternator. b. With ignition on and engine not running, connect a voltmeter between ground and terminal L, then terminal I (if used), measuring voltage at each terminal. c. If voltmeter indicates zero voltage at either terminal, locate, then correct open in circuit. d. Reconnect alternator electrical connector, then measure voltage across battery with engine running at idle and all accessories off. e. If voltage reading is more than 16 volts, replace the alternator. f. Connect an ammeter to alternator output terminal, turn accessories on, then load battery with a carbon pile to obtain maximum amperage. g. While maintaining 13 volts or more, note amperage reading. If reading is within 15 amps of rated output, the alternator is satisfactory. If reading is not within 15 amps of rated output, replace the alternator. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3898 Alternator: Component Tests and General Diagnostics Bench Testing Fig. 2 CS Alternator Bench Check 1. Make connections as shown in Fig. 2, however leave the carbon pile disconnected. The ground polarity of the alternator and battery must be the same. The battery must be fully charged. Use a 30-500 ohm resistor between battery and L terminal. 2. Slowly increase alternator speed and observe voltage. 3. If voltage is uncontrolled and increases above 16 volts, the rotor field is shorted, the regulator is defective or both. A shorted rotor field can cause the regulator to become defective. Battery must be fully charged when making this test. 4. If voltage is below 16 volts, increase speed and adjust carbon pile obtain maximum amperage output. Maintain voltage above 13 volts. 5. If output is within 15 amps of rated output, alternator is satisfactory. 6. If output is not within 15 amps of rated output, alternator is defective and requires repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3899 Testing Of CS Series Alternators - Part 1 Of 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3900 Testing Of CS Series Alternators - Part 3 Of 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3901 Testing Of CS Series Alternators - Part 2 Of 3 On-Vehicle Output Test 1. Connect ammeter in series at alternator output BAT terminal, then connect voltmeter and carbon pile across battery terminal. Ensure battery is fully charged. 2. Operate engine at moderate speed. With carbon pile turned Off, check voltage across battery terminals. 3. If voltmeter reads above 16 volts, repair (CS-144) only or replace alternator. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3902 4. If voltmeter reads below 16 volts, proceed as follows: a. With engine still running at moderate speed turn accessories On and load battery with carbon pile to obtain maximum amperage output. Maintain voltage above 13 volts. b. If output is within 15 amps of rated output, alternator is satisfactory. c. If output is not within 15 amps of rated output, alternator is defective and requires repair (CS-144 only) or replace alternator. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > CS Series Alternator Repair Alternator: Service and Repair CS Series Alternator Repair CS-121 and CS-130 Repair Procedures Do not attempt to disassemble a CS-121 or CS-130 series generator. Damage to the generator assembly could result. The CS-121 or CS-130 series generators are not repairable and must be replaced as an assembly. CS-144 Repair Procedures GENERATOR ROTOR DRIVE END BEARING Figure 2 For service of the generator rotor drive end bearing, Refer to figure 2. PULLEY DRIVE END BEARING Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > CS Series Alternator Repair > Page 3905 Figure 3 For service of the pulley drive end bearing, refer to figure 3. SLIP RING SERVICING If the slip rings are dirty, they may be cleaned and finished with 400 grain or finer polishing cloth. Spin the rotor, and hold the polishing cloth against the slip rings until they are clean. The rotor must be rotated in order to clean the slip rings evenly. Cleaning the slip rings by hand without spinning the rotor may result in flat spots on the slip rings, causing brush noise. Slip rings which are rough or out of round should be trued in a lathe to 0.002 inch maximum indicator reading. Remove only enough material to make the rings smooth and round. Finish with 400 grain or finer polishing cloth and blow away all dust. BRUSH HOLDER AND REGULATOR REPLACEMENT Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > CS Series Alternator Repair > Page 3906 Figure 1 DISASSEMBLY NOTE: Refer to figure 1. 1. Make scribe marks on end frames to facilitate reassembly. 2. Remove thru bolts and separate end frames. 3. Remove three attaching nuts and regulator attaching screws. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > CS Series Alternator Repair > Page 3907 4. Separate stator and regulator from end frame. 5. Put brushes in holder and retain in place with brush retaining wire. REASSEMBLY: 1. Place assembled brush holder in end frame with retaining wire protruding through the end frame. 2. Reverse the procedure, installing the regulator, diode trio, and stator. 3. Reassemble the two end frames with the attaching bolts. 4. With the alternator completely assembled, remove the brush retaining wire from the back of the alternator. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > CS Series Alternator Repair > Page 3908 Alternator: Service and Repair SI Series Alternator Repair Testing Of SI Series Alternators - Part 3 Of 3 RECTIFIER END BEARING REPLACEMENT Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > CS Series Alternator Repair > Page 3909 Testing Of SI Series Alternators - Part 2 Of 3 DRIVE END BEARING REPLACEMENT SLIP RING SERVICING - If the slip rings are dirty, they may be cleaned and finished with 400 grain or finer polishing cloth. Spin the rotor, and hold the polishing cloth against the slip rings until they are clean. - The rotor must be rotated in order to clean the slip rings evenly. Cleaning the slip rings by hand without spinning the rotor may result in flat spots on the slip rings, causing brush noise. - Slip rings which are rough or out of round should be trued in a lathe to 0.002 inch maximum indicator reading. Remove only enough material to make the rings smooth and round. Finish with 400 grain or finer polishing cloth and blow away all dust. BRUSH HOLDER AND REGULATOR REPLACEMENT Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > CS Series Alternator Repair > Page 3910 Testing Of SI Series Alternators - Part 1 Of 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > CS Series Alternator Repair > Page 3911 Testing Of SI Series Alternators - Part 2 Of 3 DISASSEMBLY: NOTE: Refer to figures for views. 1. Make scribe marks on end frames to facilitate reassembly. 2. Remove thru bolts and separate end frames. 3. Remove three attaching nuts and regulator attaching screws. 4. Separate stator, diode trio and regulator from end frame. 5. Put brushes in holder and retain in place with brush retaining wire. REASSEMBLY: 1. Place assembled brush holder in end frame with retaining wire protruding through the end frame. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > CS Series Alternator Repair > Page 3912 2. Reverse the procedure, installing the regulator, diode trio, and stator. 3. Reassemble the two end frames with the attaching bolts. 4. With the alternator completely assembled, remove the brush retaining wire from the back of the alternator. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Testing and Inspection Voltage Regulator: Testing and Inspection 1. Connect a voltmeter and fast charger to battery. 2. Turn ignition switch On and slowly increase charge rate. Indicator lamp in vehicle will begin to dim when voltage setting is reached. 3. Observe voltmeter, light should dim at 13.5 -16.0 volts. 4. If no voltage is present, replace voltage regulator. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Start Switch <--> [Clutch Switch] > Component Information > Locations Clutch Start Switch: Locations Below LH Side Of I/P. Behind I/P, On Clutch Pedal Support Applicable to: 1991 Cavalier w/Manual Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Start Switch <--> [Clutch Switch] > Component Information > Locations > Page 3920 Clutch Start Switch: Service and Repair 1. Disconnect clutch switch electrical connector. 2. Remove clutch bracket and switch attaching nuts, then remove switch. 3. Reverse procedure to install. Torque switch attaching nuts to 53 inch lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking Ignition Lock: Customer Interest Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3929 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3930 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3931 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3932 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3933 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3934 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 931943F > May > 93 > Ignition Lock Cylinder - Replacement Ignition Lock: All Technical Service Bulletins Ignition Lock Cylinder - Replacement Number: 93-194-3F Section: 3F Date: MAY 1993 Corporate Bulletin No.: 333207 ASE No.: A4 Subject: IGNITION LOCK CYLINDER REPLACEMENT Model and Year: 1991-93 CAVALIER SERVICE UPDATE When drilling out the ignition lock cylinder housing assembly shear bolts, care must be taken to remove the steering column from the car. Both the wiper switch and the turn signal switch must be removed before drilling the bolts out. There is a concern that metal shavings from the drilling of ignition lock cylinder shear bolts may enter the switches and cause the switch to become inoperative. The revised procedure below should be used. REMOVE 1. Steering wheel and covers (see Section 3F). 2. Steering column from vehicle (see Section 3F). 3. Turn signal switch from steering column (see Section 3F). 4. Wash/wipe switch from steering column (see Section 3F). IMPORTANT: Both the turn signal switch and wash/wipe switch have to be removed to prevent any metal shavings from entering the electrical components. 5. Lock cylinder housing assembly as follows: Put key in run position. - Drill off heads of two shear bolts using a 6.5 mm (1/4") drill bit. - Remove lock cylinder housing assembly. - Remove threaded ends of shear bolts from lock cylinder housing assembly with locking type pliers. - Clean all metal shavings from all parts after drilling. INSTALL 1. Lock cylinder housing assembly with two shear bolts. Key in run position. 2. Tighten two shear bolts until bolt head separates from bolt body approximately 11.0 N-m (97 lbs.in.) 3. Wash/wipe switch onto steering column (see Section 3F). 4. Turn signal switch onto steering column (see Section 3F). 5. Steering column into vehicle (see Section 3F). 6. Steering wheel and covers (see Section 3F). NOTE: Because the correct procedure must be followed when replacing ignition lock cylinders, Warranty will not be paid on turn signal or wiper/wash switches for 30 days after an ignition lock cylinder replacement. Use current labor time. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking Ignition Lock: All Technical Service Bulletins Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3944 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3945 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3946 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3947 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3948 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3949 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Lock: > 931943F > May > 93 > Ignition Lock Cylinder Replacement Ignition Lock: All Technical Service Bulletins Ignition Lock Cylinder - Replacement Number: 93-194-3F Section: 3F Date: MAY 1993 Corporate Bulletin No.: 333207 ASE No.: A4 Subject: IGNITION LOCK CYLINDER REPLACEMENT Model and Year: 1991-93 CAVALIER SERVICE UPDATE When drilling out the ignition lock cylinder housing assembly shear bolts, care must be taken to remove the steering column from the car. Both the wiper switch and the turn signal switch must be removed before drilling the bolts out. There is a concern that metal shavings from the drilling of ignition lock cylinder shear bolts may enter the switches and cause the switch to become inoperative. The revised procedure below should be used. REMOVE 1. Steering wheel and covers (see Section 3F). 2. Steering column from vehicle (see Section 3F). 3. Turn signal switch from steering column (see Section 3F). 4. Wash/wipe switch from steering column (see Section 3F). IMPORTANT: Both the turn signal switch and wash/wipe switch have to be removed to prevent any metal shavings from entering the electrical components. 5. Lock cylinder housing assembly as follows: Put key in run position. - Drill off heads of two shear bolts using a 6.5 mm (1/4") drill bit. - Remove lock cylinder housing assembly. - Remove threaded ends of shear bolts from lock cylinder housing assembly with locking type pliers. - Clean all metal shavings from all parts after drilling. INSTALL 1. Lock cylinder housing assembly with two shear bolts. Key in run position. 2. Tighten two shear bolts until bolt head separates from bolt body approximately 11.0 N-m (97 lbs.in.) 3. Wash/wipe switch onto steering column (see Section 3F). 4. Turn signal switch onto steering column (see Section 3F). 5. Steering column into vehicle (see Section 3F). 6. Steering wheel and covers (see Section 3F). NOTE: Because the correct procedure must be followed when replacing ignition lock cylinders, Warranty will not be paid on turn signal or wiper/wash switches for 30 days after an ignition lock cylinder replacement. Use current labor time. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder Key Sticking Ignition Switch Lock Cylinder: Customer Interest Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder Key Sticking > Page 3964 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder Key Sticking > Page 3965 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder Key Sticking > Page 3966 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder Key Sticking > Page 3967 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder Key Sticking > Page 3968 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 912943F > Apr > 91 > Ignition Lock Cylinder Key Sticking > Page 3969 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 931943F > May > 93 > Ignition Lock Cylinder - Replacement Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Replacement Number: 93-194-3F Section: 3F Date: MAY 1993 Corporate Bulletin No.: 333207 ASE No.: A4 Subject: IGNITION LOCK CYLINDER REPLACEMENT Model and Year: 1991-93 CAVALIER SERVICE UPDATE When drilling out the ignition lock cylinder housing assembly shear bolts, care must be taken to remove the steering column from the car. Both the wiper switch and the turn signal switch must be removed before drilling the bolts out. There is a concern that metal shavings from the drilling of ignition lock cylinder shear bolts may enter the switches and cause the switch to become inoperative. The revised procedure below should be used. REMOVE 1. Steering wheel and covers (see Section 3F). 2. Steering column from vehicle (see Section 3F). 3. Turn signal switch from steering column (see Section 3F). 4. Wash/wipe switch from steering column (see Section 3F). IMPORTANT: Both the turn signal switch and wash/wipe switch have to be removed to prevent any metal shavings from entering the electrical components. 5. Lock cylinder housing assembly as follows: Put key in run position. - Drill off heads of two shear bolts using a 6.5 mm (1/4") drill bit. - Remove lock cylinder housing assembly. - Remove threaded ends of shear bolts from lock cylinder housing assembly with locking type pliers. - Clean all metal shavings from all parts after drilling. INSTALL 1. Lock cylinder housing assembly with two shear bolts. Key in run position. 2. Tighten two shear bolts until bolt head separates from bolt body approximately 11.0 N-m (97 lbs.in.) 3. Wash/wipe switch onto steering column (see Section 3F). 4. Turn signal switch onto steering column (see Section 3F). 5. Steering column into vehicle (see Section 3F). 6. Steering wheel and covers (see Section 3F). NOTE: Because the correct procedure must be followed when replacing ignition lock cylinders, Warranty will not be paid on turn signal or wiper/wash switches for 30 days after an ignition lock cylinder replacement. Use current labor time. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Key Sticking Number: 91-294-3F Section: 3F Date: APRIL 1991 Corp. Bulletin No.: 173201R Subject: IGNITION KEY STICKS IN THE LOCK CYLINDER Model and Year: 1991 CAVALIER ONLY DESCRIPTION: 1991 Cavalier models equipped with a floor shift automatic transaxle use a Park Lock System. This system uses a park lock cable which is attached to the floor shift lever at one end, and the column mounted lock cylinder housing assembly at the other end. Under certain circumstances, the vehicle operator may experience a situation where the ignition key sticks in the ignition lock cylinder. Vehicles involved are as follows: Janesville Plant. Start of production through MJ132664. Lordstown Plant. Start of production through M7129428. SYSTEM CHECK PROCEDURE: Use the following procedure to check the Park Lock System and verify that the ignition key cannot be removed from the lock cylinder. 1. Place shifter in the "Park" position and turn ignition key to the "Off Lock" position. The key should be able to be removed, if you are not able to turn the key to "Off Lock" and remove the key, refer to Condition "A." 2. Check and make sure that the shifter cannot be moved from the "Park" position by depressing the shifter button and attempting to actuate the shift assembly. The shifter should not shift from park. If able to shift, refer to Condition "A." 3. Turn ignition key to the "Run" position. 4. Move the shifter to the "Neutral" position. 5. Turn ignition key to the "Off Lock" position. The iginition key rotation should stop before reaching the "Off Lock" position and the key cannot be removed from lock cylinder. If key is removable, refer to Condition "A." 6. With the key in the same position (before reaching "Off Lock"), return the shifter to the "Park" position. 7. Turn the ignition key towards the "Run" position, then to the "Off Lock" position and remove the key. 8. Replace key in the ignition lock cylinder. The Park Lock System is operating properly if all of the above steps can be completed correctly. If the ignition key still sticks in the ignition lock cylinder, go to Condition "B". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3979 Figure 1 - Lock Cylinder, Park Lock Area CONDITION A: When the shift lever is shifted to "Park," the park lock cable slider is loaded against the locking pin in the lock cylinder housing assembly. (See Figure 1). This loading prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. CAUSE A: A misadjusted park lock cable at the shifter assembly end. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3980 Figure 2 CORRECTION A: 1. Refer to the vehicle service manual for disassembly of the console. 2. With the shift lever in "Park," move the locking button on the shifter end of the park lock cable to the "Unlock" position. (See Figure 2). 3. Turn the ignition key to the "Off Lock" position and remove the key. If you are not able to remove the key, depress the shifter actuator and make sure that the adjustment body moves freely within the snap-in adjustment body. (See Figure 2) Note: Key should be able to turn to the "Off Lock" position and be removed. 4. Depress and release shifter actuator. 5. Move the locking button on the shifter end of the park lock cable to the "Lock" position. (See Figure 2). 6. Perform the system check again by following steps 1 through 8 in the "System Check Procedure." Note: If the key cannot be removed, refer to "Condition B." CONDITION B: When the shift lever is shifted to "Park," the park lock cable slider catches on a casting burr (sharp edge) in the lock cylinder housing assembly. This prevents the park lock cable slider from extending to its full "Park" position. The lock cylinder is prevented from being rotated to its "Off Lock" position. The vehicle operator cannot remove the ignition key from the lock cylinder assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3981 Figure 3 Figure 6 - Checking for the Casting Burr CAUSE B: A casting parting line of the lock cylinder housing assembly resulted in a casting burr on the bottom and left side of the rectangular slider opening on the lock cylinder housing. (See Figure 3 and Figure 6). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3982 Figure 4 CORRECTION B: Note: Two special tools are required to correct slider interference: a formed paper clip and a small triangular shaped file. (See Figure 4). Note: Refer to the vehicle service manual (Sections 3F, 3F1, and 3F2) for detailed disassembly instructions. 1. Disconnect the negative battery cable. 2. Remove the pad and disconnect the horn lead. 3. Remove the steering wheel retainer and nut. 4. Remove the steering wheel using J 1859-03. 5. Remove tilt lever from the column housing, if so equipped. 6. Remove upper cover screws and upper steering column cover. Note: Make sure that spring clips remain attached to upper cover. 7. Remove key from lock cylinder. 8. Remove lower steering column cover screws and lower steering column cover. 9. Install key in lock cylinder and turn to the "Run" position. Figure 5 10. Disconnect park lock cable from lock cylinder housing assembly by depressing locking tab with a small screwdriver (See Figure 5). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3983 Figure 6 - Checking for the Casting Burr 11. Check for a casting burr by dragging the tip of the preformed paper clip across the bottom and left surface of the park lock cable slider opening to detect any signs of a rough edge. (See Figure 6). Figure 7 - Filing to Remove the Casting Burr 12. Use a small triangular shaped file (Nicholson Swiss # 2 Triangle or equivalent) to file down the rough edges of the park lock cable slider opening as shown (See Figure 7). 13. Check that the rough edges are removed by again dragging the tip of the preformed paper clip across the surface of the park lock cable slider opening and feeling for any remaining edges of the casting burr. The end of the paper clip must not detect any sign of the burr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 912943F > Apr > 91 > Ignition Lock Cylinder - Key Sticking > Page 3984 14. Repeat steps 12 and 13 until all traces of the burr have been removed from the bottom and left sides of the slider opening. 15. From the back side of the slider opening, use oompressed air to clean the slider opening in the lock cylinder housing assembly. Make sure that no filings remain to obstruct slider or locking pin movement. 16. Install the park lock cable. Make sure the cable locking tab is firmly seated and latched in the lock cylinder housing slot. 17. Test for proper operation of the park lock system by repeating the check procedure in the "Description" section. 18. Reassemble column in reverse order. Note: Refer to the vehicle service manual for detailed reassembly instructions. WARRANTY INFORMATION: Labor Operation Number: T1714 (Adjust and remove burrs) Labor Time: 0.6 hour Labor Operation Number: K5173 (Park lock cable adjust) Use applicable labor time guide for labor hours. Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 931943F > May > 93 > Ignition Lock Cylinder - Replacement Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock Cylinder - Replacement Number: 93-194-3F Section: 3F Date: MAY 1993 Corporate Bulletin No.: 333207 ASE No.: A4 Subject: IGNITION LOCK CYLINDER REPLACEMENT Model and Year: 1991-93 CAVALIER SERVICE UPDATE When drilling out the ignition lock cylinder housing assembly shear bolts, care must be taken to remove the steering column from the car. Both the wiper switch and the turn signal switch must be removed before drilling the bolts out. There is a concern that metal shavings from the drilling of ignition lock cylinder shear bolts may enter the switches and cause the switch to become inoperative. The revised procedure below should be used. REMOVE 1. Steering wheel and covers (see Section 3F). 2. Steering column from vehicle (see Section 3F). 3. Turn signal switch from steering column (see Section 3F). 4. Wash/wipe switch from steering column (see Section 3F). IMPORTANT: Both the turn signal switch and wash/wipe switch have to be removed to prevent any metal shavings from entering the electrical components. 5. Lock cylinder housing assembly as follows: Put key in run position. - Drill off heads of two shear bolts using a 6.5 mm (1/4") drill bit. - Remove lock cylinder housing assembly. - Remove threaded ends of shear bolts from lock cylinder housing assembly with locking type pliers. - Clean all metal shavings from all parts after drilling. INSTALL 1. Lock cylinder housing assembly with two shear bolts. Key in run position. 2. Tighten two shear bolts until bolt head separates from bolt body approximately 11.0 N-m (97 lbs.in.) 3. Wash/wipe switch onto steering column (see Section 3F). 4. Turn signal switch onto steering column (see Section 3F). 5. Steering column into vehicle (see Section 3F). 6. Steering wheel and covers (see Section 3F). NOTE: Because the correct procedure must be followed when replacing ignition lock cylinders, Warranty will not be paid on turn signal or wiper/wash switches for 30 days after an ignition lock cylinder replacement. Use current labor time. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 3994 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 3995 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 3996 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Neutral Start Switch 20 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4002 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4003 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4004 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4005 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4006 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4007 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4008 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4009 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4010 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4011 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4012 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4013 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4014 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4015 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4016 Neutral Safety Switch: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4017 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4018 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4019 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4020 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4021 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Page 4022 Neutral Safety Switch: Service and Repair Disable the Supplemental Inflatable Restraint (SIR) system as described in BODY ELECTRICAL SAFETY AND ENTERTAINMENT/PASSIVE RESTRAINTS, AIR BAG/MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING prior to working on or near the steering column. 1. Disconnect battery ground cable. 2. Disconnect shift cable from transaxle. 3. Disconnect electrical connector from switch. 4. Remove two switch mounting bolts and the switch. 5. Align flats on switch with flats on transaxle shaft and push switch over shaft and fully seat on transaxle. 6. Install and torque switch mounting bolts to 20 ft. lbs. If switch was rotated and the pin broken, the switch will be automatically reset to the neutral position as follows: a. Place transaxle shaft in neutral position. b. Install switch on transaxle as outlined previously and loosely install mounting bolts. c. Insert a 3/32 inch gauge pin into service adjustment hole of switch. d. Rotate switch until pin drops in detent. e. Torque mounting bolts to 20 ft. lbs. f. Rearm airbag system as described under BODY ELECTRICAL SAFETY AND ENTERTAINMENT/PASSIVE RESTRAINTS, AIR BAG/MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive Gear > Component Information > Technical Service Bulletins > Customer Interest: > 912186D > Feb > 91 > Starter Motor - Grinding Noise/Fails to Engage Starter Drive Gear: Customer Interest Starter Motor - Grinding Noise/Fails to Engage Number: 91-218-6D Section: 6D Date: February 1991 Corporate Bulletin No.: 036404R Subject: GRINDING NOISE, NO START, STARTER FAILS TO ENGAGE Model and Year: 1990-91 CAVALIER, CORSICA, BERETTA 1991 CAPRICE, CAMARO AND LUMINA 1990 C/K, P TRUCKS 1991 S/T, M/L AND U VAN Application: Model Year Body Engine Applications (VIN) 1991 B 5.0L L03 (E) 1991 F 3.1L LH0 (T), 5.0L L03 (E), 5.0L LB9 (F) 1990 - 91 J 2.2L LM3 (G), 3.1L LH0 (T) 1990 - 91 L 2.2L LM3 (G) 1991 W 3.1L LH0 (T) TRUCKS: 1990 C/K/P 4.3L LB4 (Z) 1991 S/T/L 4.3L LB4 (Z) 1991 M 4.3L LB4 (Z & B) 1991 U 3.1L LG6 (D) CONDITION: Some owners of the above vehicles may comment on hard start, grind or clash noise during an attempted start. The starter may not properly engage the ring gear. A loud grinding noise occurs and the engine does not crank. The engine may crank normally on repeated attempts to start. CAUSE: The spring in early design SD210 / SD260 starter drives may compress too easily. This may keep the drive pinion gear from snapping into mesh with the ring gear as the starter motor starts to turn. CORRECTION: Follow the unit repair manual (Section 6D2) and replace the starter motor drive assembly with part number 10473700. Inspect the flywheel for signs of milling or material loss at the engagement points. Repair as required. The new starter drive with the stronger spring has been released for all SD210 and SD260 starters. Parts are currently available from GMSPO. Labor Operation: J4600 Use applicable Labor Time Guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912186D > Feb > 91 > Starter Motor - Grinding Noise/Fails to Engage Starter Drive Gear: All Technical Service Bulletins Starter Motor - Grinding Noise/Fails to Engage Number: 91-218-6D Section: 6D Date: February 1991 Corporate Bulletin No.: 036404R Subject: GRINDING NOISE, NO START, STARTER FAILS TO ENGAGE Model and Year: 1990-91 CAVALIER, CORSICA, BERETTA 1991 CAPRICE, CAMARO AND LUMINA 1990 C/K, P TRUCKS 1991 S/T, M/L AND U VAN Application: Model Year Body Engine Applications (VIN) 1991 B 5.0L L03 (E) 1991 F 3.1L LH0 (T), 5.0L L03 (E), 5.0L LB9 (F) 1990 - 91 J 2.2L LM3 (G), 3.1L LH0 (T) 1990 - 91 L 2.2L LM3 (G) 1991 W 3.1L LH0 (T) TRUCKS: 1990 C/K/P 4.3L LB4 (Z) 1991 S/T/L 4.3L LB4 (Z) 1991 M 4.3L LB4 (Z & B) 1991 U 3.1L LG6 (D) CONDITION: Some owners of the above vehicles may comment on hard start, grind or clash noise during an attempted start. The starter may not properly engage the ring gear. A loud grinding noise occurs and the engine does not crank. The engine may crank normally on repeated attempts to start. CAUSE: The spring in early design SD210 / SD260 starter drives may compress too easily. This may keep the drive pinion gear from snapping into mesh with the ring gear as the starter motor starts to turn. CORRECTION: Follow the unit repair manual (Section 6D2) and replace the starter motor drive assembly with part number 10473700. Inspect the flywheel for signs of milling or material loss at the engagement points. Repair as required. The new starter drive with the stronger spring has been released for all SD210 and SD260 starters. Parts are currently available from GMSPO. Labor Operation: J4600 Use applicable Labor Time Guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Drive Gear: > 91423A3C > Feb > 92 > Suspension (Front) - Squawking/Clunking Noise Stabilizer Bushing: All Technical Service Bulletins Suspension (Front) - Squawking/Clunking Noise REVISED Number: 91-423A-3C Section: 3C Date: FEB. 1992 Corporate Bulletin No.: 133304R ASE No.: A4 Subject: SQUAWK/CLUNK NOISE FROM FRONT SUSPENSION Model and Year: 1985-91 CAVALIER 1987-91 CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 92-423-3C, DATED, SEPTEMBER 1991. THE LABOR OPERATION NUMBER HAS BEEN REVISED. ALL COPIES OF 91-423-3C SHOULD BE DISCARDED. CONDITION: Some 1985-91 J/L cars might exhibit a condition of a "Squawk" OR "Clunk" noise from the front suspension or engine compartment area when driving over small bumps or entering parking lots (i.e. washboard road surfaces, railroad tracks). CAUSE: The condition may be caused by the rubber bushing material bleeding through the teflon/polyester sock and coming into contact with the stabilizer bar. CORRECTION: If this condition is encountered, replace both stabilizer bar bushings with newer designed bushings. The part numbers for the new bushings are listed below: STABILIZER BAR DIAMETER BUSHING PART NUMBER(S) 22 mm 22566673 24 mm 22566674 26 mm 22566675 28 mm 22566676 30 mm 10088389 Parts are currently available from GMSPO. WARRANTY INFORMATION: Labor Operation Number: E2180 Labor Time: See Current Labor Time Guide TROUBLE CODE: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Technical Service Bulletins > Customer Interest: > 912186D > Feb > 91 > Starter Motor - Grinding Noise/Fails to Engage Starter Drive/Bendix: Customer Interest Starter Motor - Grinding Noise/Fails to Engage Number: 91-218-6D Section: 6D Date: February 1991 Corporate Bulletin No.: 036404R Subject: GRINDING NOISE, NO START, STARTER FAILS TO ENGAGE Model and Year: 1990-91 CAVALIER, CORSICA, BERETTA 1991 CAPRICE, CAMARO AND LUMINA 1990 C/K, P TRUCKS 1991 S/T, M/L AND U VAN Application: Model Year Body Engine Applications (VIN) 1991 B 5.0L L03 (E) 1991 F 3.1L LH0 (T), 5.0L L03 (E), 5.0L LB9 (F) 1990 - 91 J 2.2L LM3 (G), 3.1L LH0 (T) 1990 - 91 L 2.2L LM3 (G) 1991 W 3.1L LH0 (T) TRUCKS: 1990 C/K/P 4.3L LB4 (Z) 1991 S/T/L 4.3L LB4 (Z) 1991 M 4.3L LB4 (Z & B) 1991 U 3.1L LG6 (D) CONDITION: Some owners of the above vehicles may comment on hard start, grind or clash noise during an attempted start. The starter may not properly engage the ring gear. A loud grinding noise occurs and the engine does not crank. The engine may crank normally on repeated attempts to start. CAUSE: The spring in early design SD210 / SD260 starter drives may compress too easily. This may keep the drive pinion gear from snapping into mesh with the ring gear as the starter motor starts to turn. CORRECTION: Follow the unit repair manual (Section 6D2) and replace the starter motor drive assembly with part number 10473700. Inspect the flywheel for signs of milling or material loss at the engagement points. Repair as required. The new starter drive with the stronger spring has been released for all SD210 and SD260 starters. Parts are currently available from GMSPO. Labor Operation: J4600 Use applicable Labor Time Guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 912186D > Feb > 91 > Starter Motor - Grinding Noise/Fails to Engage Starter Drive/Bendix: All Technical Service Bulletins Starter Motor - Grinding Noise/Fails to Engage Number: 91-218-6D Section: 6D Date: February 1991 Corporate Bulletin No.: 036404R Subject: GRINDING NOISE, NO START, STARTER FAILS TO ENGAGE Model and Year: 1990-91 CAVALIER, CORSICA, BERETTA 1991 CAPRICE, CAMARO AND LUMINA 1990 C/K, P TRUCKS 1991 S/T, M/L AND U VAN Application: Model Year Body Engine Applications (VIN) 1991 B 5.0L L03 (E) 1991 F 3.1L LH0 (T), 5.0L L03 (E), 5.0L LB9 (F) 1990 - 91 J 2.2L LM3 (G), 3.1L LH0 (T) 1990 - 91 L 2.2L LM3 (G) 1991 W 3.1L LH0 (T) TRUCKS: 1990 C/K/P 4.3L LB4 (Z) 1991 S/T/L 4.3L LB4 (Z) 1991 M 4.3L LB4 (Z & B) 1991 U 3.1L LG6 (D) CONDITION: Some owners of the above vehicles may comment on hard start, grind or clash noise during an attempted start. The starter may not properly engage the ring gear. A loud grinding noise occurs and the engine does not crank. The engine may crank normally on repeated attempts to start. CAUSE: The spring in early design SD210 / SD260 starter drives may compress too easily. This may keep the drive pinion gear from snapping into mesh with the ring gear as the starter motor starts to turn. CORRECTION: Follow the unit repair manual (Section 6D2) and replace the starter motor drive assembly with part number 10473700. Inspect the flywheel for signs of milling or material loss at the engagement points. Repair as required. The new starter drive with the stronger spring has been released for all SD210 and SD260 starters. Parts are currently available from GMSPO. Labor Operation: J4600 Use applicable Labor Time Guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Drive/Bendix: > 912633 > Mar > 91 > Dash - Squeak/Squawk Noise on Turns Steering Gear Mount: All Technical Service Bulletins Dash - Squeak/Squawk Noise on Turns Number: 91-263-3 Section: 3 Date: MARCH 1991 Corp. Bulletin No.: 133201 Subject: NOISE FROM FRONT OF DASH WHEN TURNING Model and Year: 1990-91 CAVALIER, CORSICA, BERETTA Condition: Customers may comment about a squawk/creak noise from the front of dash when turning. They may also comment about a slight feeling of vague on-center steering and slow returnability. Cause: After a extended heat soak the grommet material starts to take a compression set. This set will lead to a rub condition between the gear and the grommet during steering. Correction: As part of trouble shooting, refer to Dealer Service Bulletin No. 90-409-3 for VIN breakpoints regarding the steering gear to front of dash clamp retaining nuts and inspect them. If the retaining nuts are not loose, it may be necessary to replace only the steering gear mounting grommets. If the retaining nuts are loose, it will be necessary to replace both the retaining nuts and steering gear mounting grommets. STEERING GEAR MOUNTING REPLACEMENT GROMMETS SUSPENSION RIGHT LEFT LEVEL PART NUMBER PART NUMBER FE1 26001492 7849985 FE2 26001492 26000626 FE3 26001492 26000626 FE7 (GTZ only) 26001492 26000626 Parts are currently available from GMSPO. Vehicles with possible grommet noise conditions were produced between breakpoints listed below: From the following serial From the start of 1991 number to the end of 1990 production to the production: following serial number: "J" (Lordstown) L7166829 "J" (Lordstown) M7164949 "J" (Janesville) U244293 "J" (Janesville) MJ174173 "L" (Wilmington) LY211048 "L" (Wilmington) MY148179 "L" (Linden) LE207500 "L" (Linden) ME138400 Labor Operation Number: T1716 Labor Time: 0.9 Hour Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Delco-Remy, Hold-In and Pull-In Winding Amperes Delco-Remy, Hold-In and Pull-In Winding Amperes Hold-In Windings Pull-In Windings Starter Identification Number 10455006 13-19 A 13-19 A 10455010 12-15 A 30-36 A 10455024 13-19 A 23-30 A 10455045 13-19 A --10455046 13-19 A 23-30 A 1998524 13-19 A 23-30 A 1998525 13-19 A 23-30 A 1998527 13-19 A 23-30 A 1998580 13-19 A 23-30 A 1998591 13-19 A 23-30 A Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 4073 Starter Solenoid: Locations LH Front Of 2.2L Lower LH Front Of Engine, Above Starter Motor Applicable to: 2L/4-134 Engine. 1992 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions Starter Solenoid: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4078 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4079 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4080 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4081 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4082 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4083 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4084 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4085 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4086 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4087 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4088 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4089 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4090 Starter Solenoid: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4091 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4092 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4093 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4094 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 4095 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Diagrams > Page 4096 Starter Solenoid: Description and Operation The solenoid switch on a cranking motor not only closes the circuit between the battery and the cranking motor but also shifts the drive pinion into mesh with the engine flywheel ring gear. This is done by means of a linkage between the solenoid switch plunger and the shift lever on the cranking motor. There are two windings in the solenoid; a pull-in winding and a hold-in winding. Both windings are energized when the external control switch is closed. They produce a magnetic field which pulls the plunger in so that the drive pinion is shifted into mesh, and the main contacts in the solenoid switch are closed to connect the battery directly to the cranking motor. Closing the main switch contacts shorts out the pull-in winding since this winding is connected across the main contacts. The magnetism produced by the hold-in winding is sufficient to hold the plunger in, and shorting out the pull-in winding reduces drain on the battery. When the control switch is opened, it disconnects the hold-in winding from the battery. When the hold-in winding is disconnected from the battery, the shift lever spring withdraws the plunger from the solenoid, opening the solenoid switch contacts and at the same time withdrawing the drive pinion from mesh. Proper operation of the switch depends on maintaining a definite balance between the magnetic strength of the pull-in and hold-in windings. This balance is established in the design by the size of the wire and the number of turns specified. An open circuit in the hold-in winding or attempts to crank with a discharged battery will cause the switch to chatter. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4102 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4103 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4104 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4105 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4106 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4107 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4108 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4109 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4110 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4111 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4112 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4113 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4114 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4115 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4116 Circuit Breaker: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4117 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4118 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4119 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4120 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4121 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4122 Circuit Breaker: Electrical Diagrams Fuse Block Details: RDO 1 Fuse, S/LP Fuse, And PWR ACC Circuit Breaker Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4123 Fuse Block Details: WDO Circuit Breaker And HTR-A/C Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Isolation Diodes - Replacement Information Diode: Technical Service Bulletins Isolation Diodes - Replacement Information Number: 93-163-8A Section: 8A Date: MAY 1993 Corporate Bulletin No.: 178201R ASE No.: A6 Subject: ISOLATION DIODES REPLACEMENT INFORMATION Model and Year: 1993 AND PRIOR YEAR PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 92-47-8A, DATED NOV. 1991. THE 1993 MODEL YEAR HAS BEEN ADDED AS WELL AS PART NUMBERS HAVE BEEN REVISED. THIS WILL ALSO UPDATE CERTAIN SERVICE MANUALS. ALL COPIES OF 92-47-8A SHOULD BE DISCARDED. Many of the electrical systems on our vehicles use a diode to isolate certain circuits and protect them from voltage spikes. Some of the circuits which may use such a diode are listed below: A/C Compressor Clutch ABS/4WAL NOTE: The ABS diode on the Delco Moraine system is hidden inside of an electrical connector under the carpet at the right kick panel. Wiper Charging System (hidden in wire harness) Parking Brake (vehicles with ABS) Relays Solenoids Diesel Glow Plug Circuit Day Time Running Lights Obtaining replacement diodes can sometimes be a problem. A universal diode, that meets the specifications in the chart below, may be used for the applications listed above. Since certain diode applications have specific part numbers, always reference the applicable GM parts catalogue before installing one of the universal diodes listed in this bulletin. When installing the new diode, use the following procedures to obtain a lasting repair: 1. If the diode is taped to the harness, remove all of the tape. 2. Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. 3. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 4. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. Reference Figure 1 for replacement diode symbols and current flow explanations. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Isolation Diodes - Replacement Information > Page 4128 Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a heat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturers instructions for the solderin equipment you are using. 5. Install terminal(s) into the connector body if previously removed in step number 2. 6. Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion completely cover all exposed wire and diode attachment points. NOTE: A universal diode with a 3 amp, 400 PIV (Peak Inverse Voltage) rating can be used in all of the previously mentioned applications. The following 1993 Service Manuals will need to be updated with the correct part numbers and rating changes. Carline Page All J, L, W, and UO 8A-5-12 Heat sink, part number 276-1567, can be obtained from Radio Shack. We believe the diodes and heat sink listed in this article as well as their manufacturer to be reliable. There may be additional manufacturers or equivalent 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. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > DRL In-Line Fuse A Fuse: Locations DRL In-Line Fuse A LH Side Of Engine Compartment. LH Side Of Engine Compartment, By Strut Tower Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > DRL In-Line Fuse A > Page 4135 Fuse: Locations DRL In-Line Fuse B LH Side Of Engine Compartment. LH Side Of Engine Compartment, By Strut Tower Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > DRL In-Line Fuse A > Page 4136 Fuse: Locations Fuel Pump Inline Fuse LH Front Of 3. LH Front Of Dash On Relay Bracket Applicable to: 1L/V6-192 Dash. 1991 Sunbird Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4144 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4145 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4146 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4147 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4148 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 Fuse: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4157 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4158 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4159 Fuse: Electrical Diagrams Fuse Block Details: Wiper Fuse, Cruise Fuse And RDO 2 Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4160 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/U Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4161 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/u Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4162 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/U Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4163 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/u Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4164 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/U Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4165 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/u Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4166 Fuse Block Details: WDO Circuit Breaker And HTR-A/C Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4167 Fuse Block Details: RDO 1 Fuse, S/LP Fuse, And PWR ACC Circuit Breaker Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4168 Fuse Block Details: Wiper Fuse, Cruise Fuse And RDO 2 Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4169 Fuse Block Details: RDO 1 Fuse, S/LP Fuse, And PWR ACC Circuit Breaker Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4170 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/U Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4171 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/u Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4172 Fuse Block Details: Wiper Fuse, Cruise Fuse And RDO 2 Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Convenience Center Location. Behind I/P, Near Top Of LH Shroud Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Link A Fusible Link: Locations Fusible Link A LH Front Of 2. Engine Harness, At Starter Solenoid Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Link A > Page 4180 Fusible Link: Locations Fusible Link B LH Front Of 2.2L At Starter Solenoid Applicable to: 2L/4-134 Engine. 1992 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Link A > Page 4181 Fusible Link: Locations Fusible Link C LH Front Of 2.2L At Starter Solenoid Applicable to: 2L/4-134 Engine. 1992 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Link A > Page 4182 Fusible Link: Locations Fusible Link E LH Front Of 2. At Starter Solenoid Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Link A > Page 4183 Fusible Link: Locations Fusible Link A LH Front Of 2. Engine Harness, At Starter Solenoid Applicable to: 2L/4-134 Engine. 1991 Cavalier Fusible Link B LH Front Of 2.2L At Starter Solenoid Applicable to: 2L/4-134 Engine. 1992 Cavalier Fusible Link C Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Link A > Page 4184 LH Front Of 2.2L At Starter Solenoid Applicable to: 2L/4-134 Engine. 1992 Cavalier Fusible Link E LH Front Of 2. At Starter Solenoid Applicable to: 2L/4-134 Engine. 1991 Cavalier Fusible Link G LH Front Of 2. At Starter Solenoid Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Link A > Page 4185 Applicable to: 2L/4-134 Engine. 1991 Cavalier Fusible Link L LH Front Of Dash, At Battery Junction Block Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4190 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4191 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4192 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4193 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4194 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4195 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power > Page 4204 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 4210 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 91858A > Oct > 90 > Electrical Connectors - Service Procedure Multiple Junction Connector: All Technical Service Bulletins Electrical Connectors - Service Procedure Number: 91-85-8A Section: 8A Date: October 1990 Corp. Bulletin No.: 018115 Subject: PROCEDURE FOR CHECKING CONNECTOR TERMINAL CONTACT Model and Year: 1982-91 PASSENGER CARS AND TRUCKS Figure 1 TO: ALL CHEVROLET DEALERS Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 91858A > Oct > 90 > Electrical Connectors - Service Procedure > Page 4215 When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit J 38125-4 instruction manual for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: "Check for poor connection or replace...". Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually to underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, see Figure 1, causing an open or intermittently open circuit. Follow the procedure below to check terminal contact. 1. Separate the connector halves, refer to Terminal Repair Kit J 38125-4 instruction manual. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals causing high terminal resistance, intermittent connection or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety, terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit J 38125-2, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit J 38125-2, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question, refer to Terminal Repair Kit J 38125-2. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multiple Junction Connector: > 91858A > Oct > 90 > Electrical Connectors - Service Procedure Multiple Junction Connector: All Technical Service Bulletins Electrical Connectors - Service Procedure Number: 91-85-8A Section: 8A Date: October 1990 Corp. Bulletin No.: 018115 Subject: PROCEDURE FOR CHECKING CONNECTOR TERMINAL CONTACT Model and Year: 1982-91 PASSENGER CARS AND TRUCKS Figure 1 TO: ALL CHEVROLET DEALERS Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multiple Junction Connector: > 91858A > Oct > 90 > Electrical Connectors - Service Procedure > Page 4221 When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit J 38125-4 instruction manual for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: "Check for poor connection or replace...". Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually to underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, see Figure 1, causing an open or intermittently open circuit. Follow the procedure below to check terminal contact. 1. Separate the connector halves, refer to Terminal Repair Kit J 38125-4 instruction manual. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals causing high terminal resistance, intermittent connection or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety, terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit J 38125-2, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit J 38125-2, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question, refer to Terminal Repair Kit J 38125-2. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4230 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4231 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4232 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 4237 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4243 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4244 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4245 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4250 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4251 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4252 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4253 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4254 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4255 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 4260 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4265 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4271 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4272 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4273 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4274 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4275 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4276 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4281 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4287 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4288 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4289 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4290 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4291 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4292 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4293 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4294 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4295 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4296 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4297 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4298 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4299 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4300 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4301 Circuit Breaker: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4302 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4303 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4304 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4305 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4306 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4307 Circuit Breaker: Electrical Diagrams Fuse Block Details: RDO 1 Fuse, S/LP Fuse, And PWR ACC Circuit Breaker Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4308 Fuse Block Details: WDO Circuit Breaker And HTR-A/C Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Isolation Diodes - Replacement Information Diode: Technical Service Bulletins Isolation Diodes - Replacement Information Number: 93-163-8A Section: 8A Date: MAY 1993 Corporate Bulletin No.: 178201R ASE No.: A6 Subject: ISOLATION DIODES REPLACEMENT INFORMATION Model and Year: 1993 AND PRIOR YEAR PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 92-47-8A, DATED NOV. 1991. THE 1993 MODEL YEAR HAS BEEN ADDED AS WELL AS PART NUMBERS HAVE BEEN REVISED. THIS WILL ALSO UPDATE CERTAIN SERVICE MANUALS. ALL COPIES OF 92-47-8A SHOULD BE DISCARDED. Many of the electrical systems on our vehicles use a diode to isolate certain circuits and protect them from voltage spikes. Some of the circuits which may use such a diode are listed below: A/C Compressor Clutch ABS/4WAL NOTE: The ABS diode on the Delco Moraine system is hidden inside of an electrical connector under the carpet at the right kick panel. Wiper Charging System (hidden in wire harness) Parking Brake (vehicles with ABS) Relays Solenoids Diesel Glow Plug Circuit Day Time Running Lights Obtaining replacement diodes can sometimes be a problem. A universal diode, that meets the specifications in the chart below, may be used for the applications listed above. Since certain diode applications have specific part numbers, always reference the applicable GM parts catalogue before installing one of the universal diodes listed in this bulletin. When installing the new diode, use the following procedures to obtain a lasting repair: 1. If the diode is taped to the harness, remove all of the tape. 2. Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. 3. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 4. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. Reference Figure 1 for replacement diode symbols and current flow explanations. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Isolation Diodes - Replacement Information > Page 4313 Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a heat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturers instructions for the solderin equipment you are using. 5. Install terminal(s) into the connector body if previously removed in step number 2. 6. Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion completely cover all exposed wire and diode attachment points. NOTE: A universal diode with a 3 amp, 400 PIV (Peak Inverse Voltage) rating can be used in all of the previously mentioned applications. The following 1993 Service Manuals will need to be updated with the correct part numbers and rating changes. Carline Page All J, L, W, and UO 8A-5-12 Heat sink, part number 276-1567, can be obtained from Radio Shack. We believe the diodes and heat sink listed in this article as well as their manufacturer to be reliable. There may be additional manufacturers or equivalent 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. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > DRL In-Line Fuse A Fuse: Locations DRL In-Line Fuse A LH Side Of Engine Compartment. LH Side Of Engine Compartment, By Strut Tower Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > DRL In-Line Fuse A > Page 4320 Fuse: Locations DRL In-Line Fuse B LH Side Of Engine Compartment. LH Side Of Engine Compartment, By Strut Tower Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > DRL In-Line Fuse A > Page 4321 Fuse: Locations Fuel Pump Inline Fuse LH Front Of 3. LH Front Of Dash On Relay Bracket Applicable to: 1L/V6-192 Dash. 1991 Sunbird Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4324 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4325 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4326 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4327 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4328 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4329 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4330 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4331 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4332 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4333 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4334 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4335 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4336 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4337 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4338 Fuse: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4339 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4340 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4341 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4342 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4343 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4344 Fuse: Electrical Diagrams Fuse Block Details: Wiper Fuse, Cruise Fuse And RDO 2 Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4345 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/U Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4346 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/u Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4347 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/U Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4348 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/u Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4349 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/U Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4350 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/u Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4351 Fuse Block Details: WDO Circuit Breaker And HTR-A/C Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4352 Fuse Block Details: RDO 1 Fuse, S/LP Fuse, And PWR ACC Circuit Breaker Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4353 Fuse Block Details: Wiper Fuse, Cruise Fuse And RDO 2 Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4354 Fuse Block Details: RDO 1 Fuse, S/LP Fuse, And PWR ACC Circuit Breaker Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4355 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/U Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4356 Fuse Block Details: Gages Fuse, F/P Fuse, Turn B/u Fuse And ECM Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4357 Fuse Block Details: Wiper Fuse, Cruise Fuse And RDO 2 Fuse Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Convenience Center Location. Behind I/P, Near Top Of LH Shroud Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Link A Fusible Link: Locations Fusible Link A LH Front Of 2. Engine Harness, At Starter Solenoid Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Link A > Page 4365 Fusible Link: Locations Fusible Link B LH Front Of 2.2L At Starter Solenoid Applicable to: 2L/4-134 Engine. 1992 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Link A > Page 4366 Fusible Link: Locations Fusible Link C LH Front Of 2.2L At Starter Solenoid Applicable to: 2L/4-134 Engine. 1992 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Link A > Page 4367 Fusible Link: Locations Fusible Link E LH Front Of 2. At Starter Solenoid Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Link A > Page 4368 Fusible Link: Locations Fusible Link A LH Front Of 2. Engine Harness, At Starter Solenoid Applicable to: 2L/4-134 Engine. 1991 Cavalier Fusible Link B LH Front Of 2.2L At Starter Solenoid Applicable to: 2L/4-134 Engine. 1992 Cavalier Fusible Link C Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Link A > Page 4369 LH Front Of 2.2L At Starter Solenoid Applicable to: 2L/4-134 Engine. 1992 Cavalier Fusible Link E LH Front Of 2. At Starter Solenoid Applicable to: 2L/4-134 Engine. 1991 Cavalier Fusible Link G LH Front Of 2. At Starter Solenoid Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fusible Link A > Page 4370 Applicable to: 2L/4-134 Engine. 1991 Cavalier Fusible Link L LH Front Of Dash, At Battery Junction Block Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4375 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4376 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4377 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4378 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4379 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4380 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 4389 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 4395 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 91858A > Oct > 90 > Electrical Connectors - Service Procedure Multiple Junction Connector: All Technical Service Bulletins Electrical Connectors - Service Procedure Number: 91-85-8A Section: 8A Date: October 1990 Corp. Bulletin No.: 018115 Subject: PROCEDURE FOR CHECKING CONNECTOR TERMINAL CONTACT Model and Year: 1982-91 PASSENGER CARS AND TRUCKS Figure 1 TO: ALL CHEVROLET DEALERS Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 91858A > Oct > 90 > Electrical Connectors - Service Procedure > Page 4400 When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit J 38125-4 instruction manual for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: "Check for poor connection or replace...". Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually to underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, see Figure 1, causing an open or intermittently open circuit. Follow the procedure below to check terminal contact. 1. Separate the connector halves, refer to Terminal Repair Kit J 38125-4 instruction manual. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals causing high terminal resistance, intermittent connection or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety, terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit J 38125-2, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit J 38125-2, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question, refer to Terminal Repair Kit J 38125-2. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multiple Junction Connector: > 91858A > Oct > 90 > Electrical Connectors - Service Procedure Multiple Junction Connector: All Technical Service Bulletins Electrical Connectors - Service Procedure Number: 91-85-8A Section: 8A Date: October 1990 Corp. Bulletin No.: 018115 Subject: PROCEDURE FOR CHECKING CONNECTOR TERMINAL CONTACT Model and Year: 1982-91 PASSENGER CARS AND TRUCKS Figure 1 TO: ALL CHEVROLET DEALERS Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multiple Junction Connector: > 91858A > Oct > 90 > Electrical Connectors - Service Procedure > Page 4406 When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit J 38125-4 instruction manual for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: "Check for poor connection or replace...". Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually to underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, see Figure 1, causing an open or intermittently open circuit. Follow the procedure below to check terminal contact. 1. Separate the connector halves, refer to Terminal Repair Kit J 38125-4 instruction manual. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals causing high terminal resistance, intermittent connection or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety, terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit J 38125-2, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit J 38125-2, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question, refer to Terminal Repair Kit J 38125-2. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4415 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4416 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4417 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 4422 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4428 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4429 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4430 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4435 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4436 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4437 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4438 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4439 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4440 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 4445 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4450 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4456 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4457 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4458 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4459 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4460 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4461 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4466 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Diagnostic Procedures Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4476 Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4477 condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4478 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4479 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4480 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4481 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications Alignment: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications > Page 4487 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications > Page 4488 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications > Page 4489 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications > Page 4490 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications > Page 4491 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications > Page 4492 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 05-03-07-009C > Dec > 10 > Steering/Suspension - Wheel Alignment Specifications > Page 4493 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Diagnostic Procedures Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4498 Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4499 condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4500 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4501 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4502 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4503 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned Alignment: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned > Page 4509 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned > Page 4510 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned > Page 4511 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned > Page 4512 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned > Page 4513 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned > Page 4514 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned > Page 4515 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4516 Alignment: By Symptom Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Diagnostic Procedures Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4517 Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4518 condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4519 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4520 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4521 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4522 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4523 Diagnostic Procedures Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4524 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4525 A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4526 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4527 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4528 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4529 Diagnostic Procedures Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4530 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4531 A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4532 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4533 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4534 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front Alignment Specifications Front Wheel Alignment Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front Alignment Specifications > Page 4537 Rear Wheel Alignment Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Caster Adjustment Alignment: Service and Repair Front Caster Adjustment Caster is not adjustable. If caster angle is not within specifications, inspect for suspension support misalignment or front suspension damage. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Caster Adjustment > Page 4540 Alignment: Service and Repair Front Camber Adjustment Fig. 1 Modifying Strut Bracket To Adjust Camber Toe setting is the only adjustment normally required. However, in special circumstances, such as damage due to road hazard or collision, camber may be adjusted by modifying the strut assembly. 1. Secure bottom of strut assembly in a suitable vise. 2. Enlarge bottom holes in outer flanges with a round file until holes in outer flanges match slots in inner flanges, Fig. 1. 3. Connect strut to steering knuckle and install bolts finger tight. 4. Grasp top of tire firmly, then move tire inboard or outboard until correct camber reading is obtained. Tighten retaining bolts enough to secure camber setting. 5. Remove wheel and tire and tighten strut to steering knuckle retaining bolts. On 1989-90 models, Torque strut to steering knuckle retaining bolts to 135 ft. lbs. On 1991-92 models, Torque strut to steering knuckle attaching bolt to 133 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Caster Adjustment > Page 4541 Alignment: Service and Repair Front Toe Adjustment Fig. 2 Adjusting Toe Toe-out is controlled by tie rod position. Adjustment is made by loosening the clamp bolts at the steering knuckle end of the tie rods and rotating the rods to obtain proper toe setting, Fig. 2. After correct toe setting is obtained, tighten clamp bolts. Torque clamp bolts to 41 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations RH Rear Of Engine Compartment. LH Front Of Dash, Below Brake Booster Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 4547 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch The Power Steering Pressure Switch (PSPS) opens during high pressure power steering situations. When the power steering switch is open, power to the A/C relay is shut off, resulting in air conditioning compressor clutch disengagement. A signal is also sent to the ECM. The ECM uses this signal for idle speed control. A Scan tool should read "off" normally, and "on" with high pressure. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair 1. Raise and support vehicle, then remove wheel and tire. 2. Remove front hub and bearing as outlined under WHEEL BEARING procedure. 3. Using tool J-29330, on 1989-90 models or J-38892, on 1991-92 models, separate ball joint from steering knuckle. 4. Remove strut to steering knuckle attaching bolts, then disconnect strut from steering knuckle. 5. Assemble strut to new steering knuckle and install attaching bolts finger tight. 6. Insert ball joint stud into steering knuckle and torque stud nut to specification. 7. Torque strut to steering knuckle bolts to specification. 8. Reverse removal procedure to complete installation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold Power Steering Fluid: Customer Interest P/S - Reduced Assist When Cold Group Ref.: Steering/Suspension Bulletin No.: 033206 Date: March 1994 SUBJECT: REDUCED POWER STEERING ASSIST AT LOW AMBIENT TEMPERATURES (NEW POWER STEERING FLUID) MODELS: 1994 AND PRIOR PASSENGER CARS AND LIGHT DUTY TRUCKS Applications: Appropriate for all passenger vehicles, but particularly beneficial in 1980 and later FWD Models equipped with Power Rack and Pinion Steering. CONDITION: Comments of reduced power steering assist at low ambient temperatures (approximately 10°F and lower) may be noted by some vehicle operators when turning the steering wheel in BOTH the right and left direction during warm-up after cold start. All vehicles with power steering exhibit this condition to varying degrees, but condition may be more noticeable with power rack and pinion steering systems that typically have longer hoses and cooler lines. Note: This condition, which is related to power steering fluid viscosity, should not, however, be confused with conditions having similar symptoms such as that described divisional Special Policy numbers listed: CAUSE: In cold weather, power steering fluid thickens in the same manner as any other petroleum-based oil or fluid. Upon cold starting, the fluid resists movement through the system and the driver senses reduced power assist (sometimes referred to as "stiff steer"). As the vehicle operates and fluid circulates through the power steering system, the fluid warms and thins to its normal operating viscosity. CORRECTION: Saginaw Division has developed a new Low Temperature Climate Service Fluid for use in cold climates. Compared with conventional power steering fluid, this new fluid flows better at low temperatures and resists the thickening which contributes to reduced power assist upon start up. RACK AND PINION STEERING SYSTEMS Reduced power assist upon cold weather starting may be more noticeable in Power Rack and Pinion steering systems that may contain six or more feet of Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold > Page 4561 pressure and return hose along with long cooler lines. Such long systems contain greater volumes of fluid and vehicles so equipped tend to have longer periods of reduced power assist. The new fluid performs particularly well with current designed Rack and Pinion steering systems and special remanufactured Rack and Pinion Steering Assemblies. PARTS INFORMATION: Low Temperature Climate Service Fluid is available from GMSPO. Order as: Parts are currently available from GMSPO. SERVICE PROCEDURE: The power steering fluid replacement procedure is a two-stage process: first, flushing the old fluid from the system with new fluid; and second, bleeding the system to remove any trapped air. The two sequences outline the steps in each procedure. FLUSHING THE POWER STEERING SYSTEM 1. Raise the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the fluid return line at the pump reservoir inlet connector. 3. Plug the inlet connector port on the pump reservoir. 4. Position the fluid return line toward a large container in order to catch the draining fluid. 5. While a second person fills the reservoir with new Low Temperature Climate Service Fluid, start and run the engine at idle. 6. Turn the steering wheel from stop to stop. NOTICE: Do not hold the wheel against stops while flushing the system, Holding steering wheel against wheel stops will cause high system pressure, overheating, and damage to the pump and/or gear. 7. Continue draining until all of the old fluid is cleared from the power steering system. Addition of approximately 1 quart of new fluid will be required to flush system. 8. Unplug pump reservoir inlet and reconnect return line. 9. Turn engine off, and fill reservoir to the "Full Cold" mark. 10. Continue with following procedure "Bleeding the Power Steering System". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold > Page 4562 BLEEDING THE POWER STEERING SYSTEM After replacing the fluid or servicing the power steering hydraulic system, you must bleed air from the system. Air in the system prevents an accurate fluid level reading, causes pump cavitation noise and over time could damage the pump. To bleed the power steering system proceed as follows: 1. Begin with the engine off, front wheels off the ground, and wheels turned all the way to the left. 2. Add Low Temperature Climate Service Fluid to the "FULL COLD" mark on the fluid level indicator. 3. Bleed the system by turning the wheels from side to side without hitting stops. Important: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold > Page 4563 This may require turning the wheels from side to side twenty times. On systems with long return lines or fluid coolers, turning steering wheel lock-to-lock forty times may be required. Keep the fluid level at the "FULL COLD" mark. Fluid with air In it has a light tan appearance. This air must be eliminated from the fluid before normal steering action can be obtained. 4. Start the engine. With the engine idling, recheck the fluid level. If necessary, add fluid to bring the level to the "FULL COLD" mark. 5. Return the wheels to the center position. Lower front wheels to the ground. Continue running the engine for two or three minutes. 6. Test the vehicle to be sure the steering functions normally and is free from noise. Important: Inspect for fluid leakage at connection points along the power steering system. 7. Recheck the fluid level as described in Steps 3 and 4 except that the fluid level should now be up to the "FULL HOT" mark after the system has stabilized at its normal operating temperature. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid: > 912083B > Feb > 91 > Power Steering - Reduced Assist At Low Temperatures Power Steering Fluid: Customer Interest Power Steering - Reduced Assist At Low Temperatures Number: 91-208-3B Section: 3B FEBRUARY 1991 Date: Corporate Bulletin No.: 033206R Subject: REDUCED POWER STEERING ASSIST AT LOW AMBIENT TEMPERATURES Model and Year: ALL 1980-91 PASSENGER CARS Applications Appropriate for all passenger vehicles, but particularly beneficial in 1980 and later FWD Models equipped with Power Rack and Pinion Steering. CONDITION Comments of reduced power steering assist at low ambient temperatures (approximately 10 degrees Fahrenheit and lower) may be noted by some vehicle operators when turning the steering wheel in BOTH the right and left direction during warm-up after cold start. All vehicles with power steering exhibit this condition to varying degrees, but condition may be more noticeable with power rack and pinion steering systems that typically have longer hoses and cooler lines. Note: This condition, which is related to power steering fluid viscosity, should not, however, be confused with conditions having similiar symptoms such as that described in divisional bulletins indicated below, related to internal steering gear fluid by-pass. Chevrolet # 88-417-3B CAUSE: In cold weather, power steering fluid thickens in the same manner as any other petroleumbased oil or fluid. Upon cold starting, the fluid resists movement through the system and the driver senses reduced power assist (sometimes referred to as "stiff steer"). As the vehicle operates and fluid circulates through the power steering system, the fluid warms and thins to its normal operating viscosity. CORRECTION: Saginaw Division has developed a new Low Temperature Climate Service Fluid for use in cold climates. Compared with conventional power steering fluid, this new fluid flows better at low temperatures and resists the thickening which contributes to reduced power assist upon start up. RACK AND PINION STEERING SYSTEMS Reduced power assist upon cold weather starting may be more noticeable in Power Rack and Pinion steering systems that may contain six or more feet of pressure and return hose along with long cooler lines. Such long systems contain greater volumes of fluid and vehicles so equipped tend to have longer periods of reduced power assist. The new fluid performs particularly well with current designed Rack and Pinion steering systems and special remanufactured Rack and Pinion Steering Assemblies. PARTS INFORMATION: Low Temperature Climate Service Fluid is available from GMSPO. Order as: Container Size Part Number 16 ounce 12345866 32 ounce 12345867 Parts are currently available from GMSPO. SERVICE PROCEDURE: The power steering fluid replacement procedure is a two-stage process: first, flushing the old fluid from the system with new fluid; and second, bleeding the system to remove any trapped air. The following two sequences outline the steps in each procedure. FLUSHING THE POWER STEERING SYSTEM Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid: > 912083B > Feb > 91 > Power Steering - Reduced Assist At Low Temperatures > Page 4568 1. Raise the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the fluid return line at the pump reservoir inlet connector. 3. Plug the inlet connector port on the pump reservoir. 4. Position the fluid return line toward a large container in order to catch the draining fluid. 5. While a second person fills the reservoir with new Low Temperature Climate Service Fluid, start and run the engine at idle. 6. Turn the steering wheel from stop to stop. NOTICE: Do not hold the wheel against stops while flushing the system. Holding steering wheel against wheel stops will cause high system pressure, overheating, and damage to the pump and/or gear. 7. Continue draining until all of the old fluid is cleared from the power steering system. Addition of approximately 1 quart of new fluid will be required to flush system. 8. Unplug pump reservoir inlet and reconnect return line. 9. Turn engine off, and fill reservoir to the "Full Cold" mark. 9. Continue with following procedure "Bleeding the Power Steering System". BLEEDING THE POWER STEERING SYSTEM After replacing the fluid or servicing the power steering hydraulic system, you must bleed air from the system. Air in the system prevents an accurate fluid level reading, causes pump cavitation noise and over time could damage the pump. To bleed the power steering system proceed as follows: 1. Begin with the engine off, front wheels off the ground, and wheels turned all the way to the left. 2. Add Low Temperature Climate Service Fluid to the "FULL COLD" mark on the fluid level indicator. 3. Bleed the system by turning the wheels from side to side without hitting stops. IMPORTANT:This may require turning the wheels from side to side several times. Keep the fluid level at the "FULL COLD" mark. Fluid with air in it has a light tan appearance. This air must be eliminated from the fluid before normal steering action can be obtained. 4. Start the engine. With the engine idling, recheck the fluid level. If necessary, add fluid to bring the level to the "FULL COLD" mark. 5. Return the wheels to the center position. Lower front wheels to the ground. Continue running the engine for two or three minutes. 6. Test the vehicle to be sure the steering functions normally and is free from noise. IMPORTANT:Inspect for fluid leakage at connection points along the power steering system. 7. Recheck the fluid level as described in Steps 3 and 4 except that the fluid level should now be up to the "FULL HOT" mark after the system has stabilized at its normal operating temperature. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold Power Steering Fluid: All Technical Service Bulletins P/S - Reduced Assist When Cold Group Ref.: Steering/Suspension Bulletin No.: 033206 Date: March 1994 SUBJECT: REDUCED POWER STEERING ASSIST AT LOW AMBIENT TEMPERATURES (NEW POWER STEERING FLUID) MODELS: 1994 AND PRIOR PASSENGER CARS AND LIGHT DUTY TRUCKS Applications: Appropriate for all passenger vehicles, but particularly beneficial in 1980 and later FWD Models equipped with Power Rack and Pinion Steering. CONDITION: Comments of reduced power steering assist at low ambient temperatures (approximately 10°F and lower) may be noted by some vehicle operators when turning the steering wheel in BOTH the right and left direction during warm-up after cold start. All vehicles with power steering exhibit this condition to varying degrees, but condition may be more noticeable with power rack and pinion steering systems that typically have longer hoses and cooler lines. Note: This condition, which is related to power steering fluid viscosity, should not, however, be confused with conditions having similar symptoms such as that described divisional Special Policy numbers listed: CAUSE: In cold weather, power steering fluid thickens in the same manner as any other petroleum-based oil or fluid. Upon cold starting, the fluid resists movement through the system and the driver senses reduced power assist (sometimes referred to as "stiff steer"). As the vehicle operates and fluid circulates through the power steering system, the fluid warms and thins to its normal operating viscosity. CORRECTION: Saginaw Division has developed a new Low Temperature Climate Service Fluid for use in cold climates. Compared with conventional power steering fluid, this new fluid flows better at low temperatures and resists the thickening which contributes to reduced power assist upon start up. RACK AND PINION STEERING SYSTEMS Reduced power assist upon cold weather starting may be more noticeable in Power Rack and Pinion steering systems that may contain six or more feet of Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold > Page 4574 pressure and return hose along with long cooler lines. Such long systems contain greater volumes of fluid and vehicles so equipped tend to have longer periods of reduced power assist. The new fluid performs particularly well with current designed Rack and Pinion steering systems and special remanufactured Rack and Pinion Steering Assemblies. PARTS INFORMATION: Low Temperature Climate Service Fluid is available from GMSPO. Order as: Parts are currently available from GMSPO. SERVICE PROCEDURE: The power steering fluid replacement procedure is a two-stage process: first, flushing the old fluid from the system with new fluid; and second, bleeding the system to remove any trapped air. The two sequences outline the steps in each procedure. FLUSHING THE POWER STEERING SYSTEM 1. Raise the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the fluid return line at the pump reservoir inlet connector. 3. Plug the inlet connector port on the pump reservoir. 4. Position the fluid return line toward a large container in order to catch the draining fluid. 5. While a second person fills the reservoir with new Low Temperature Climate Service Fluid, start and run the engine at idle. 6. Turn the steering wheel from stop to stop. NOTICE: Do not hold the wheel against stops while flushing the system, Holding steering wheel against wheel stops will cause high system pressure, overheating, and damage to the pump and/or gear. 7. Continue draining until all of the old fluid is cleared from the power steering system. Addition of approximately 1 quart of new fluid will be required to flush system. 8. Unplug pump reservoir inlet and reconnect return line. 9. Turn engine off, and fill reservoir to the "Full Cold" mark. 10. Continue with following procedure "Bleeding the Power Steering System". Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold > Page 4575 BLEEDING THE POWER STEERING SYSTEM After replacing the fluid or servicing the power steering hydraulic system, you must bleed air from the system. Air in the system prevents an accurate fluid level reading, causes pump cavitation noise and over time could damage the pump. To bleed the power steering system proceed as follows: 1. Begin with the engine off, front wheels off the ground, and wheels turned all the way to the left. 2. Add Low Temperature Climate Service Fluid to the "FULL COLD" mark on the fluid level indicator. 3. Bleed the system by turning the wheels from side to side without hitting stops. Important: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 033206 > Mar > 94 > P/S - Reduced Assist When Cold > Page 4576 This may require turning the wheels from side to side twenty times. On systems with long return lines or fluid coolers, turning steering wheel lock-to-lock forty times may be required. Keep the fluid level at the "FULL COLD" mark. Fluid with air In it has a light tan appearance. This air must be eliminated from the fluid before normal steering action can be obtained. 4. Start the engine. With the engine idling, recheck the fluid level. If necessary, add fluid to bring the level to the "FULL COLD" mark. 5. Return the wheels to the center position. Lower front wheels to the ground. Continue running the engine for two or three minutes. 6. Test the vehicle to be sure the steering functions normally and is free from noise. Important: Inspect for fluid leakage at connection points along the power steering system. 7. Recheck the fluid level as described in Steps 3 and 4 except that the fluid level should now be up to the "FULL HOT" mark after the system has stabilized at its normal operating temperature. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 912083B > Feb > 91 > Power Steering - Reduced Assist At Low Temperatures Power Steering Fluid: All Technical Service Bulletins Power Steering - Reduced Assist At Low Temperatures Number: 91-208-3B Section: 3B FEBRUARY 1991 Date: Corporate Bulletin No.: 033206R Subject: REDUCED POWER STEERING ASSIST AT LOW AMBIENT TEMPERATURES Model and Year: ALL 1980-91 PASSENGER CARS Applications Appropriate for all passenger vehicles, but particularly beneficial in 1980 and later FWD Models equipped with Power Rack and Pinion Steering. CONDITION Comments of reduced power steering assist at low ambient temperatures (approximately 10 degrees Fahrenheit and lower) may be noted by some vehicle operators when turning the steering wheel in BOTH the right and left direction during warm-up after cold start. All vehicles with power steering exhibit this condition to varying degrees, but condition may be more noticeable with power rack and pinion steering systems that typically have longer hoses and cooler lines. Note: This condition, which is related to power steering fluid viscosity, should not, however, be confused with conditions having similiar symptoms such as that described in divisional bulletins indicated below, related to internal steering gear fluid by-pass. Chevrolet # 88-417-3B CAUSE: In cold weather, power steering fluid thickens in the same manner as any other petroleumbased oil or fluid. Upon cold starting, the fluid resists movement through the system and the driver senses reduced power assist (sometimes referred to as "stiff steer"). As the vehicle operates and fluid circulates through the power steering system, the fluid warms and thins to its normal operating viscosity. CORRECTION: Saginaw Division has developed a new Low Temperature Climate Service Fluid for use in cold climates. Compared with conventional power steering fluid, this new fluid flows better at low temperatures and resists the thickening which contributes to reduced power assist upon start up. RACK AND PINION STEERING SYSTEMS Reduced power assist upon cold weather starting may be more noticeable in Power Rack and Pinion steering systems that may contain six or more feet of pressure and return hose along with long cooler lines. Such long systems contain greater volumes of fluid and vehicles so equipped tend to have longer periods of reduced power assist. The new fluid performs particularly well with current designed Rack and Pinion steering systems and special remanufactured Rack and Pinion Steering Assemblies. PARTS INFORMATION: Low Temperature Climate Service Fluid is available from GMSPO. Order as: Container Size Part Number 16 ounce 12345866 32 ounce 12345867 Parts are currently available from GMSPO. SERVICE PROCEDURE: The power steering fluid replacement procedure is a two-stage process: first, flushing the old fluid from the system with new fluid; and second, bleeding the system to remove any trapped air. The following two sequences outline the steps in each procedure. FLUSHING THE POWER STEERING SYSTEM Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 912083B > Feb > 91 > Power Steering - Reduced Assist At Low Temperatures > Page 4581 1. Raise the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the fluid return line at the pump reservoir inlet connector. 3. Plug the inlet connector port on the pump reservoir. 4. Position the fluid return line toward a large container in order to catch the draining fluid. 5. While a second person fills the reservoir with new Low Temperature Climate Service Fluid, start and run the engine at idle. 6. Turn the steering wheel from stop to stop. NOTICE: Do not hold the wheel against stops while flushing the system. Holding steering wheel against wheel stops will cause high system pressure, overheating, and damage to the pump and/or gear. 7. Continue draining until all of the old fluid is cleared from the power steering system. Addition of approximately 1 quart of new fluid will be required to flush system. 8. Unplug pump reservoir inlet and reconnect return line. 9. Turn engine off, and fill reservoir to the "Full Cold" mark. 9. Continue with following procedure "Bleeding the Power Steering System". BLEEDING THE POWER STEERING SYSTEM After replacing the fluid or servicing the power steering hydraulic system, you must bleed air from the system. Air in the system prevents an accurate fluid level reading, causes pump cavitation noise and over time could damage the pump. To bleed the power steering system proceed as follows: 1. Begin with the engine off, front wheels off the ground, and wheels turned all the way to the left. 2. Add Low Temperature Climate Service Fluid to the "FULL COLD" mark on the fluid level indicator. 3. Bleed the system by turning the wheels from side to side without hitting stops. IMPORTANT:This may require turning the wheels from side to side several times. Keep the fluid level at the "FULL COLD" mark. Fluid with air in it has a light tan appearance. This air must be eliminated from the fluid before normal steering action can be obtained. 4. Start the engine. With the engine idling, recheck the fluid level. If necessary, add fluid to bring the level to the "FULL COLD" mark. 5. Return the wheels to the center position. Lower front wheels to the ground. Continue running the engine for two or three minutes. 6. Test the vehicle to be sure the steering functions normally and is free from noise. IMPORTANT:Inspect for fluid leakage at connection points along the power steering system. 7. Recheck the fluid level as described in Steps 3 and 4 except that the fluid level should now be up to the "FULL HOT" mark after the system has stabilized at its normal operating temperature. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 914083B > Aug > 91 > Power Steering Shudder/Moan or Vibration Power Steering Line/Hose: Customer Interest Power Steering - Shudder/Moan or Vibration Number: 91-408-3B Section: 3B Date: AUGUST 1991 Corporate Bulletin No.: 133209R ASE No.: A4 Subject: POWER STEERING SHUDDER Model and Year: 1989 CAVALIER, CORSICA AND BERETTA WITH 2.0L AND 2.8L ENGINES 1990 CAVALIER, CORSICA AND BERETTA WITH 2.2L, 2.3L AND 3.1L ENGINES 1991 CAVALIER, CORSICA AND BERETTA WITH 2.2L AND 3.1L ENGINES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-326-3B, DATED AUGUST 1990. THE 1991 MODEL YEAR HAS BEEN ADDED AS WELL AS THE CAVALIER AND CORSICA VEHICLES. ALSO, ADDITIONAL INFORMATION HAS BEEN ADDED. ALL COPIES OF 90-326-3B SHOULD BE DISCARDED. MODELS/YEARS: 1990-91 "J" and "L" w/2.2L (VIN G) engine 1990-91 "J" and "L" w/3.1L (VIN T) engine 1990 "L" w/2.3L (VIN A) engine 1989 "J" and "L" w/2.0L (VIN 1) engine 1989 "J" and "L" w/2.8L (VIN W) engine Condition: Customers may comment about a shudder, moan or vibration that occurs when turning the steering wheel under the following conditions: - Vehicle stopped with brake applied (or moving very slowly) - Vehicle in gear - Engine at idle speed The shudder or moan may occur during parking maneuvers or other situations when the steering wheel is turned while the vehicle is stopped or moving very slowly. It is also sensitive to steering wheel rotational speed as well as engine speed. The shudder is commonly more severe during hot ambient temperatures. Cause: A combination of steering gear valve instability and/or engine firing pulses generating a disturbance that is transmitted through the body structure. Correction: Install a "tuned" power steering return hose and/or high expansion pressure hose between the steering pump and gear. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 914083B > Aug > 91 > Power Steering Shudder/Moan or Vibration > Page 4590 1990-91 "J" w/2.2L (VIN G) engine 1989 "J" w/2.0L (VIN 1) engine This condition may be repaired by installing a "tuned" return hose, P/N 26025260. J-cars built during the 1991 model year already have the "tuned" return hose. If a 1990 2.2L J-car already equipped with a tuned return hose, or a 1991 2.2L J-car exhibits the shudder, install a high expansion pressure hose, P/N 26029284. 1990-91 "J" w/3.1L (VIN T) engine 1989 "J" w/2.8L (VIN W) engine Starting with the following VIN breakpoints, 1991 model vehicles are being built with a new high expansion pressure hose which corrects this condition. Vehicles built BEFORE the VIN breakpoints listed below may be repaired by installing a new high expansion pressure hose, P/N 26026623. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 914083B > Aug > 91 > Power Steering Shudder/Moan or Vibration > Page 4591 (Lordstown) M7117613 1990-91 "L" w/2.2L (VIN G) engine 1989 "L" w/2.0L (VIN 1) engine This condition may be repaired by installing a tuned return hose, P/N 26006690. "L" cars built during the 1991 model year already have the tuned return hose. If a 1990 2.2L L-car already equipped with a tuned return hose, or a 1991 2.2L L-car exhibits the shudder, install a high expansion pressure hose, P/N 26029284. 1990 - 91 "L" w/3.1L (VIN T) engine 1989 "L" w/2.8L (VIN W) engine Starting with the following VIN breakpoints, 1991 model vehicles are being built with a new high expansion pressure hose which repairs this condition. Vehicles built before the VIN breakpoints listed below may be repaired by installing a new high pressure expansion hose, P/N 26028229. (Linden) ME178914 (Wilmington) MY219301 1990 "L" w/2.3L (VIN A) engine Starting with the following VIN breakpoint, 1990 vehicles are equipped with a "tuned" return hose which helps this condition. Vehicles built before this VIN breakpoint, may be repaired by installing a new "tuned" return hose, P/N 26024663. (Wilmington) LY223211 Note: If the above hoses do not repair the shudder condition, please contact Technical Assistance. Parts are currently available from GMSPO. Labor Operation Number: Pressure Hose E8622 Labor Time : See Current Labor Time Guide Trouble Code : 92 Labor Operation Number: Return Hose E8623 Labor Time : See Current Labor Time Guide Trouble Code : 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 914083B > Aug > 91 > Power Steering - Shudder/Moan or Vibration Power Steering Line/Hose: All Technical Service Bulletins Power Steering - Shudder/Moan or Vibration Number: 91-408-3B Section: 3B Date: AUGUST 1991 Corporate Bulletin No.: 133209R ASE No.: A4 Subject: POWER STEERING SHUDDER Model and Year: 1989 CAVALIER, CORSICA AND BERETTA WITH 2.0L AND 2.8L ENGINES 1990 CAVALIER, CORSICA AND BERETTA WITH 2.2L, 2.3L AND 3.1L ENGINES 1991 CAVALIER, CORSICA AND BERETTA WITH 2.2L AND 3.1L ENGINES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-326-3B, DATED AUGUST 1990. THE 1991 MODEL YEAR HAS BEEN ADDED AS WELL AS THE CAVALIER AND CORSICA VEHICLES. ALSO, ADDITIONAL INFORMATION HAS BEEN ADDED. ALL COPIES OF 90-326-3B SHOULD BE DISCARDED. MODELS/YEARS: 1990-91 "J" and "L" w/2.2L (VIN G) engine 1990-91 "J" and "L" w/3.1L (VIN T) engine 1990 "L" w/2.3L (VIN A) engine 1989 "J" and "L" w/2.0L (VIN 1) engine 1989 "J" and "L" w/2.8L (VIN W) engine Condition: Customers may comment about a shudder, moan or vibration that occurs when turning the steering wheel under the following conditions: - Vehicle stopped with brake applied (or moving very slowly) - Vehicle in gear - Engine at idle speed The shudder or moan may occur during parking maneuvers or other situations when the steering wheel is turned while the vehicle is stopped or moving very slowly. It is also sensitive to steering wheel rotational speed as well as engine speed. The shudder is commonly more severe during hot ambient temperatures. Cause: A combination of steering gear valve instability and/or engine firing pulses generating a disturbance that is transmitted through the body structure. Correction: Install a "tuned" power steering return hose and/or high expansion pressure hose between the steering pump and gear. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 914083B > Aug > 91 > Power Steering - Shudder/Moan or Vibration > Page 4597 1990-91 "J" w/2.2L (VIN G) engine 1989 "J" w/2.0L (VIN 1) engine This condition may be repaired by installing a "tuned" return hose, P/N 26025260. J-cars built during the 1991 model year already have the "tuned" return hose. If a 1990 2.2L J-car already equipped with a tuned return hose, or a 1991 2.2L J-car exhibits the shudder, install a high expansion pressure hose, P/N 26029284. 1990-91 "J" w/3.1L (VIN T) engine 1989 "J" w/2.8L (VIN W) engine Starting with the following VIN breakpoints, 1991 model vehicles are being built with a new high expansion pressure hose which corrects this condition. Vehicles built BEFORE the VIN breakpoints listed below may be repaired by installing a new high expansion pressure hose, P/N 26026623. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 914083B > Aug > 91 > Power Steering - Shudder/Moan or Vibration > Page 4598 (Lordstown) M7117613 1990-91 "L" w/2.2L (VIN G) engine 1989 "L" w/2.0L (VIN 1) engine This condition may be repaired by installing a tuned return hose, P/N 26006690. "L" cars built during the 1991 model year already have the tuned return hose. If a 1990 2.2L L-car already equipped with a tuned return hose, or a 1991 2.2L L-car exhibits the shudder, install a high expansion pressure hose, P/N 26029284. 1990 - 91 "L" w/3.1L (VIN T) engine 1989 "L" w/2.8L (VIN W) engine Starting with the following VIN breakpoints, 1991 model vehicles are being built with a new high expansion pressure hose which repairs this condition. Vehicles built before the VIN breakpoints listed below may be repaired by installing a new high pressure expansion hose, P/N 26028229. (Linden) ME178914 (Wilmington) MY219301 1990 "L" w/2.3L (VIN A) engine Starting with the following VIN breakpoint, 1990 vehicles are equipped with a "tuned" return hose which helps this condition. Vehicles built before this VIN breakpoint, may be repaired by installing a new "tuned" return hose, P/N 26024663. (Wilmington) LY223211 Note: If the above hoses do not repair the shudder condition, please contact Technical Assistance. Parts are currently available from GMSPO. Labor Operation Number: Pressure Hose E8622 Labor Time : See Current Labor Time Guide Trouble Code : 92 Labor Operation Number: Return Hose E8623 Labor Time : See Current Labor Time Guide Trouble Code : 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 921078A > Feb > 92 > Cruise Control - Intermittent Dropout/Fail to Set/Resume Cruise Control Servo: All Technical Service Bulletins Cruise Control - Intermittent Dropout/Fail to Set/Resume Number: 92-107-8A Section: 8A Date: FEB. 1992 Corporate Bulletin No.: 239001 ASE No.: A8 Subject: CRUISE CONTROL INTERMITTENT DROP-OUT AND/OR FAIL TO SET OR RESUME Model and Year: 1988-92 ALL PASSENGER CARS AND TRUCKS EXCEPT CAPRICE IS 1988-90 ONLY CONDITION: On 1988-92 vehicles using the vacuum servo cruise control system, the cruise control may intermittently lose speed and/or drop-out (release), while using cruise control. It may also fail to initially set, or resume, at times. Vehicles using the Electro-Motor Cruise Control system (Stepper Motor Cruise) are not affected. When driving the vehicle, the cruise control will operate normally for 10 to 30 miles, then may gradually lose speed and/or drop out of cruise. If you experience this condition, accelerate to a speed higher than the cruise set speed, using the accelerator pedal only. DO NOT use the set or resume controls. Then allow the vehicle to coast down, and see whether the cruise catches and holds at the set speed. If the cruise catches and holds at the set speed, the diagnostic procedure below should be used to test the servo and vacuum system. Because of the intermittent nature of this condition, you may have to try several times to reproduce this condition. CAUSE: In a small percentage of servos, the vent valve, which normally cycles to control the amount of vacuum needed to maintain a set speed, may fail to close at times. When this happens, the vacuum is being continually vented, so the servo cannot pull the throttle open to increase the vehicle speed. The valve may close correctly the next time the cruise is cycled by setting or resuming. Because this condition is intermittent, testing the vehicle following the Service Manual diagnostic procedures may lead to the replacement of good parts, which will not correct the vehicle. This may lead to the customer having to bring the vehicle back for service again. It is recommended that the following diagnostic procedure be performed to determine if the trouble can be found. DIAGNOSTIC PROCEDURE: First evaluate the cruise system as specified in the Service Manual. Then make the following additional checks that may detect conditions with the vacuum portion of the cruise system. Source Vacuum Check: Disconnect the vacuum supply hose from the servo (small hose). Install a vacuum gage at the hose end and start the engine. The gage should read at least 10 in. Hg. (34 Kp/m2). If there is no vacuum, or very little vacuum, inspect for leaking or pinched hoses. Servo Vacuum Valve Check: With engine off, remove the vacuum supply hose (small hose) from the servo. Using a hand held vacuum pump connected to the vacuum port on the servo, stroke the pump until the gage reads 10-15 in.Hg. (34 - 50 Kp/m2). Replace the servo if either of the following conditions occur: 1. Vacuum valve will not hold any vacuum. 2. Gage reads 10-15 in.HG. (34 - 50 Kp/m2), but vacuum may decrease quickly (less than 10 seconds). In a good servo, the vacuum may decrease slowly (more than 30 seconds). Servo Vent Valve Check: Disconnect the servo from the throttle linkage. Disconnect the electrical connector from the servo. Using a fused jumper wire, apply 12 volts to terminal "A" on the servo. Connect a jumper wire from terminal "C" on the servo to ground. You should hear a click noise as the vent valve closes. Remove the vacuum release valve hose (large hose) from the servo. Using a hand held vacuum pump connected to the large port, stroke the pump until the servo diaphragm pulls in and the gage reads 10-20 in.Hg. (34 - 68 Kp/m2). Replace the servo if either of the following conditions occur: 1. Diaphragm will not move in completely. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 921078A > Feb > 92 > Cruise Control - Intermittent Dropout/Fail to Set/Resume > Page 4604 2. Diaphragm moves in completely. Gauge reads 10-15 in.Hg. (34 - 50 Kp/m2), but vacuum decreases quickly (In a good servo the vacuum may decrease slowly). Vacuum Release Valve (On Brake Pedal) Check: Disconnect the vacuum release hose from the servo (large hose). Apply vacuum (10-20 in.Hg. (34-68 Kp/m2)) to the hose using a hand vacuum pump and gage. The vacuum reading on the gage should remain steady. If gage reading does not hold, or leaks down slowly, inspect for a leaking or misadjusted vacuum release valve (at the brake pedal), or a leaking hose. A leaking vacuum release system will dramatically effect the operation and life of the servo. Other items that could affect servo life and operation are: - Improper servo cable or rod adjustment; - Binding throftle linkage; - Loose or bent servo bracket; or - Poor electrical connections. If the previous diagnostic procedures fail to determine the cause of the cruise system intermittent condition, replace the servo. WARRANTY INFORMATION: Use Labor Operation T1821, Labor Time: 0.5 hrs., for diagnostic time only Use existing labor operations for replacement of parts. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 921078A > Feb > 92 > Cruise Control - Intermittent Dropout/Fail to Set/Resume > Page 4610 2. Diaphragm moves in completely. Gauge reads 10-15 in.Hg. (34 - 50 Kp/m2), but vacuum decreases quickly (In a good servo the vacuum may decrease slowly). Vacuum Release Valve (On Brake Pedal) Check: Disconnect the vacuum release hose from the servo (large hose). Apply vacuum (10-20 in.Hg. (34-68 Kp/m2)) to the hose using a hand vacuum pump and gage. The vacuum reading on the gage should remain steady. If gage reading does not hold, or leaks down slowly, inspect for a leaking or misadjusted vacuum release valve (at the brake pedal), or a leaking hose. A leaking vacuum release system will dramatically effect the operation and life of the servo. Other items that could affect servo life and operation are: - Improper servo cable or rod adjustment; - Binding throftle linkage; - Loose or bent servo bracket; or - Poor electrical connections. If the previous diagnostic procedures fail to determine the cause of the cruise system intermittent condition, replace the servo. WARRANTY INFORMATION: Use Labor Operation T1821, Labor Time: 0.5 hrs., for diagnostic time only Use existing labor operations for replacement of parts. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 914083B > Aug > 91 > Power Steering - Shudder/Moan or Vibration Power Steering Pressure Control Valve: Customer Interest Power Steering - Shudder/Moan or Vibration Number: 91-408-3B Section: 3B Date: AUGUST 1991 Corporate Bulletin No.: 133209R ASE No.: A4 Subject: POWER STEERING SHUDDER Model and Year: 1989 CAVALIER, CORSICA AND BERETTA WITH 2.0L AND 2.8L ENGINES 1990 CAVALIER, CORSICA AND BERETTA WITH 2.2L, 2.3L AND 3.1L ENGINES 1991 CAVALIER, CORSICA AND BERETTA WITH 2.2L AND 3.1L ENGINES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-326-3B, DATED AUGUST 1990. THE 1991 MODEL YEAR HAS BEEN ADDED AS WELL AS THE CAVALIER AND CORSICA VEHICLES. ALSO, ADDITIONAL INFORMATION HAS BEEN ADDED. ALL COPIES OF 90-326-3B SHOULD BE DISCARDED. MODELS/YEARS: 1990-91 "J" and "L" w/2.2L (VIN G) engine 1990-91 "J" and "L" w/3.1L (VIN T) engine 1990 "L" w/2.3L (VIN A) engine 1989 "J" and "L" w/2.0L (VIN 1) engine 1989 "J" and "L" w/2.8L (VIN W) engine Condition: Customers may comment about a shudder, moan or vibration that occurs when turning the steering wheel under the following conditions: - Vehicle stopped with brake applied (or moving very slowly) - Vehicle in gear - Engine at idle speed The shudder or moan may occur during parking maneuvers or other situations when the steering wheel is turned while the vehicle is stopped or moving very slowly. It is also sensitive to steering wheel rotational speed as well as engine speed. The shudder is commonly more severe during hot ambient temperatures. Cause: A combination of steering gear valve instability and/or engine firing pulses generating a disturbance that is transmitted through the body structure. Correction: Install a "tuned" power steering return hose and/or high expansion pressure hose between the steering pump and gear. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 914083B > Aug > 91 > Power Steering - Shudder/Moan or Vibration > Page 4619 1990-91 "J" w/2.2L (VIN G) engine 1989 "J" w/2.0L (VIN 1) engine This condition may be repaired by installing a "tuned" return hose, P/N 26025260. J-cars built during the 1991 model year already have the "tuned" return hose. If a 1990 2.2L J-car already equipped with a tuned return hose, or a 1991 2.2L J-car exhibits the shudder, install a high expansion pressure hose, P/N 26029284. 1990-91 "J" w/3.1L (VIN T) engine 1989 "J" w/2.8L (VIN W) engine Starting with the following VIN breakpoints, 1991 model vehicles are being built with a new high expansion pressure hose which corrects this condition. Vehicles built BEFORE the VIN breakpoints listed below may be repaired by installing a new high expansion pressure hose, P/N 26026623. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 914083B > Aug > 91 > Power Steering - Shudder/Moan or Vibration > Page 4620 (Lordstown) M7117613 1990-91 "L" w/2.2L (VIN G) engine 1989 "L" w/2.0L (VIN 1) engine This condition may be repaired by installing a tuned return hose, P/N 26006690. "L" cars built during the 1991 model year already have the tuned return hose. If a 1990 2.2L L-car already equipped with a tuned return hose, or a 1991 2.2L L-car exhibits the shudder, install a high expansion pressure hose, P/N 26029284. 1990 - 91 "L" w/3.1L (VIN T) engine 1989 "L" w/2.8L (VIN W) engine Starting with the following VIN breakpoints, 1991 model vehicles are being built with a new high expansion pressure hose which repairs this condition. Vehicles built before the VIN breakpoints listed below may be repaired by installing a new high pressure expansion hose, P/N 26028229. (Linden) ME178914 (Wilmington) MY219301 1990 "L" w/2.3L (VIN A) engine Starting with the following VIN breakpoint, 1990 vehicles are equipped with a "tuned" return hose which helps this condition. Vehicles built before this VIN breakpoint, may be repaired by installing a new "tuned" return hose, P/N 26024663. (Wilmington) LY223211 Note: If the above hoses do not repair the shudder condition, please contact Technical Assistance. Parts are currently available from GMSPO. Labor Operation Number: Pressure Hose E8622 Labor Time : See Current Labor Time Guide Trouble Code : 92 Labor Operation Number: Return Hose E8623 Labor Time : See Current Labor Time Guide Trouble Code : 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 914083B > Aug > 91 > Power Steering - Shudder/Moan or Vibration Power Steering Pressure Control Valve: All Technical Service Bulletins Power Steering Shudder/Moan or Vibration Number: 91-408-3B Section: 3B Date: AUGUST 1991 Corporate Bulletin No.: 133209R ASE No.: A4 Subject: POWER STEERING SHUDDER Model and Year: 1989 CAVALIER, CORSICA AND BERETTA WITH 2.0L AND 2.8L ENGINES 1990 CAVALIER, CORSICA AND BERETTA WITH 2.2L, 2.3L AND 3.1L ENGINES 1991 CAVALIER, CORSICA AND BERETTA WITH 2.2L AND 3.1L ENGINES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-326-3B, DATED AUGUST 1990. THE 1991 MODEL YEAR HAS BEEN ADDED AS WELL AS THE CAVALIER AND CORSICA VEHICLES. ALSO, ADDITIONAL INFORMATION HAS BEEN ADDED. ALL COPIES OF 90-326-3B SHOULD BE DISCARDED. MODELS/YEARS: 1990-91 "J" and "L" w/2.2L (VIN G) engine 1990-91 "J" and "L" w/3.1L (VIN T) engine 1990 "L" w/2.3L (VIN A) engine 1989 "J" and "L" w/2.0L (VIN 1) engine 1989 "J" and "L" w/2.8L (VIN W) engine Condition: Customers may comment about a shudder, moan or vibration that occurs when turning the steering wheel under the following conditions: - Vehicle stopped with brake applied (or moving very slowly) - Vehicle in gear - Engine at idle speed The shudder or moan may occur during parking maneuvers or other situations when the steering wheel is turned while the vehicle is stopped or moving very slowly. It is also sensitive to steering wheel rotational speed as well as engine speed. The shudder is commonly more severe during hot ambient temperatures. Cause: A combination of steering gear valve instability and/or engine firing pulses generating a disturbance that is transmitted through the body structure. Correction: Install a "tuned" power steering return hose and/or high expansion pressure hose between the steering pump and gear. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 914083B > Aug > 91 > Power Steering - Shudder/Moan or Vibration > Page 4626 1990-91 "J" w/2.2L (VIN G) engine 1989 "J" w/2.0L (VIN 1) engine This condition may be repaired by installing a "tuned" return hose, P/N 26025260. J-cars built during the 1991 model year already have the "tuned" return hose. If a 1990 2.2L J-car already equipped with a tuned return hose, or a 1991 2.2L J-car exhibits the shudder, install a high expansion pressure hose, P/N 26029284. 1990-91 "J" w/3.1L (VIN T) engine 1989 "J" w/2.8L (VIN W) engine Starting with the following VIN breakpoints, 1991 model vehicles are being built with a new high expansion pressure hose which corrects this condition. Vehicles built BEFORE the VIN breakpoints listed below may be repaired by installing a new high expansion pressure hose, P/N 26026623. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 914083B > Aug > 91 > Power Steering - Shudder/Moan or Vibration > Page 4627 (Lordstown) M7117613 1990-91 "L" w/2.2L (VIN G) engine 1989 "L" w/2.0L (VIN 1) engine This condition may be repaired by installing a tuned return hose, P/N 26006690. "L" cars built during the 1991 model year already have the tuned return hose. If a 1990 2.2L L-car already equipped with a tuned return hose, or a 1991 2.2L L-car exhibits the shudder, install a high expansion pressure hose, P/N 26029284. 1990 - 91 "L" w/3.1L (VIN T) engine 1989 "L" w/2.8L (VIN W) engine Starting with the following VIN breakpoints, 1991 model vehicles are being built with a new high expansion pressure hose which repairs this condition. Vehicles built before the VIN breakpoints listed below may be repaired by installing a new high pressure expansion hose, P/N 26028229. (Linden) ME178914 (Wilmington) MY219301 1990 "L" w/2.3L (VIN A) engine Starting with the following VIN breakpoint, 1990 vehicles are equipped with a "tuned" return hose which helps this condition. Vehicles built before this VIN breakpoint, may be repaired by installing a new "tuned" return hose, P/N 26024663. (Wilmington) LY223211 Note: If the above hoses do not repair the shudder condition, please contact Technical Assistance. Parts are currently available from GMSPO. Labor Operation Number: Pressure Hose E8622 Labor Time : See Current Labor Time Guide Trouble Code : 92 Labor Operation Number: Return Hose E8623 Labor Time : See Current Labor Time Guide Trouble Code : 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - System Bleed Procedures Power Steering Pump: Technical Service Bulletins Steering - System Bleed Procedures Group Ref.: Steering/Suspension Bulletin No.: 383001 Date: December, 1993 INFORMATION SUBJECT: ILLUSTRATED STEERING SYSTEM BLEED PROCEDURE MODELS: 1994 AND PRIOR PASSENGER CARS AND LIGHT DUTY TRUCKS THIS BULLETIN IS BEING REVISED TO ADD THE 1994 MODEL YEAR AND CHANGE THE ARTWORK. PREVIOUS DIVISIONAL PUBLICATION NUMBERS WERE: BUICK 93-3-5 3/02/93 CADILLAC T-93-76 5/12/93 CHEVROLET 93-146-3B 3/29/93 GM OF CANADA 93-3-102 5/05/93 OLDSMOBILE 2-93-59 (S.G.) 5/14/93 The steering system in 1994 and prior model year cars and light duty trucks should be bled after any of the following: - A power steering component is replaced. - A fluid line is disconnected. - A customer comments on steering system noise. Bleeding air from the steering system should be done in order to prevent pump damage, ensure proper operation, and to eliminate steering system noise. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - System Bleed Procedures > Page 4632 The illustration presents a pictorial illustration of the bleed procedure. This new procedure replaces previous steering system bleed procedures. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - System Bleed Procedures > Page 4633 SERVICE PARTS INFORMATION Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal/Installation Power Steering Pump: Service and Repair Removal/Installation 1. Disconnect battery ground cable. 2. Remove serpentine belt. 3. Remove power steering pump attaching pressure lines. 4. Remove power steering pump attaching bolts. 5. Remove pump assembly, then transfer power steering pump pulley. 6. Reverse to install. Torque attaching bolts to specifications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal/Installation > Page 4636 Power Steering Pump: Service and Repair Disassembly/Assembly CB Series Pump Fig. 5 Exploded View Of CB Series Power Steering Pump Fig. 6 Removing Return Tube. CB Series Power Steering Pump Disassembly 1. Disconnect battery ground cable, then remove power steering pump from vehicle. Refer to individual car chapters for procedures. 2. Remove union fitting with O-ring and the O-ring seal, Fig. 5. 3. Remove control valve assembly and flow control spring. 4. Protect driveshaft with shim stock and remove driveshaft seal by cutting with small chisel. Discard seal. 5. Remove return tube using tap, nut and washers, Fig. 6, as follows. Plug return tube to prevent chips from entering pump. a. Stack five 5/8 inch washers onto return tube. b. Run one 9/16 inch-12 nut midway up a 9/16 inch 12 tap. c. Install threaded end of tap into return tube until nut is positioned against washers. d. Using wrench, hold top stationary while turning nut clockwise. 6. Remove end cover retaining ring by inserting punch in access hole. 7. Gently push on driveshaft to assist in removing end cover, O-ring, pressure plate spring, pump ring, pump vanes and the driveshaft subassembly, consisting of pump rotor, thrust plate, driveshaft and shaft retaining ring. 8. Remove O-ring from housing. 9. Remove dowel pins, then the driveshaft seal if not previously removed. 10. Remove pressure plate, pressure plate spring and O-ring from end cover. 11. Remove shaft retaining ring from driveshaft, then the pump rotor and thrust plate. Inspection Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal/Installation > Page 4637 1. Clean all parts in power steering fluid, then dry thoroughly. 2. Inspect pump ring, vanes, thrust plate, pressure plate and driveshaft for scoring, pitting or chatter marks, replacing parts as necessary. Fig. 7 Installing Rotor And/or Pump Ring. CB Series Power Steering Pump Assembly 1. Lubricate new driveshaft seal with power steering fluid and, using seal installer, tool No. J 7728 or equivalent, press driveshaft seal into pump housing. 2. Install pump ring dowel pins into housing. 3. Install thrust plate and pump rotor onto driveshaft, Fig. 7. 4. Install new shaft retaining ring onto driveshaft. 5. Install driveshaft subassembly into housing. 6. Install pump ring, with holes positioned correctly onto dowel pins, Fig. 7, in housing. 7. Install vanes into pump rotor. 8. Lubricate new O-ring (large) with power steering fluid and install O-ring into end cover. 9. Install pressure plate and pressure plate spring. 10. Lubricate new O-ring (small) and install O-ring into end cover. 11. Lubricate outer edge of end cover with power steering fluid and press end cover into housing. 12. Insert retaining ring into groove in housing, with ring opening near access hole opening. 13. Remove plug and any chips, then coat end of new return tube with Loctite solvent 75559 and Loctite 290 adhesive, or equivalents, and press return tube into housing until bottomed. Jidosha Kiki This pump is only serviced as an assembly, except for relief valve and pulley. N & P Series Pump Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal/Installation > Page 4638 Fig. 8 Power Steering Pump Assembly Overhaul (Part 1 Of 2). N & P Series Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal/Installation > Page 4639 Fig. 8 Power Steering Pump Assembly Overhaul (Part 2 Of 2). N & P Series Refer to Fig. 8 for service procedures on this power steering pump. P Series L/Reservoir Pump Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal/Installation > Page 4640 Fig. 9 Power Steering Pump Assembly Overhaul (Part 1 Of 2). P Series, L/reservoir Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal/Installation > Page 4641 Fig. 9 Power Steering Pump Assembly Overhaul (Part 2 Of 2). P Series, L/reservoir Refer to Fig. 9 for service procedures on this power steering pump. TC Series Pump Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal/Installation > Page 4642 Fig. 10 Power Steering Pump Assembly Overhaul (Part 1 Of 4). TC Series Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal/Installation > Page 4643 Fig. 10 Power Steering Pump Assembly Overhaul (Part 2 Of 4). TC Series Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal/Installation > Page 4644 Fig. 10 Power Steering Pump Assembly Overhaul (Part 3 Of 4). TC Series Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal/Installation > Page 4645 Fig. 10 Power Steering Pump Assembly Overhaul (Part 4 Of 4). TC Series Refer to Fig. 10 for service procedures on this power steering pump. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations RH Rear Of Engine Compartment. LH Front Of Dash, Below Brake Booster Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 4650 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch The Power Steering Pressure Switch (PSPS) opens during high pressure power steering situations. When the power steering switch is open, power to the A/C relay is shut off, resulting in air conditioning compressor clutch disengagement. A signal is also sent to the ECM. The ECM uses this signal for idle speed control. A Scan tool should read "off" normally, and "on" with high pressure. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling the SIR System Air Bag(s) Arming and Disarming: Service and Repair Disabling the SIR System The diagnostic energy reserve module (DERM) can maintain voltage to cause a system deployment for up to ten minutes after the ignition switch is turned off and the battery is disconnected. Servicing the SIR system during this period may result in accidental deployment and personal injury. 1. Ensure front wheels are pointed straight ahead. 2. Turn ignition switch to Lock position and remove SIR or AIRBAG fuse. 3. Remove lower left sound insulator. 4. Remove connector position assurance (CPA) lock and disconnect yellow two-way SIR harness connector at base of steering column. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling the SIR System > Page 4656 Air Bag(s) Arming and Disarming: Service and Repair Enabling the SIR System 1. Connect yellow two-way SIR harness connector and install CPA lock. 2. Install left sound insulator. 3. Install SIR fuse. 4. Turn ignition switch to Run position and ensure ``Inflatable Restraint'' lamp flashes 7-9 times and then remains off. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > Customer Interest for Steering Gear Mount: > 912633 > Mar > 91 > Dash Squeak/Squawk Noise on Turns Steering Gear Mount: Customer Interest Dash - Squeak/Squawk Noise on Turns Number: 91-263-3 Section: 3 Date: MARCH 1991 Corp. Bulletin No.: 133201 Subject: NOISE FROM FRONT OF DASH WHEN TURNING Model and Year: 1990-91 CAVALIER, CORSICA, BERETTA Condition: Customers may comment about a squawk/creak noise from the front of dash when turning. They may also comment about a slight feeling of vague on-center steering and slow returnability. Cause: After a extended heat soak the grommet material starts to take a compression set. This set will lead to a rub condition between the gear and the grommet during steering. Correction: As part of trouble shooting, refer to Dealer Service Bulletin No. 90-409-3 for VIN breakpoints regarding the steering gear to front of dash clamp retaining nuts and inspect them. If the retaining nuts are not loose, it may be necessary to replace only the steering gear mounting grommets. If the retaining nuts are loose, it will be necessary to replace both the retaining nuts and steering gear mounting grommets. STEERING GEAR MOUNTING REPLACEMENT GROMMETS SUSPENSION RIGHT LEFT LEVEL PART NUMBER PART NUMBER FE1 26001492 7849985 FE2 26001492 26000626 FE3 26001492 26000626 FE7 (GTZ only) 26001492 26000626 Parts are currently available from GMSPO. Vehicles with possible grommet noise conditions were produced between breakpoints listed below: From the following serial From the start of 1991 number to the end of 1990 production to the production: following serial number: "J" (Lordstown) L7166829 "J" (Lordstown) M7164949 "J" (Janesville) U244293 "J" (Janesville) MJ174173 "L" (Wilmington) LY211048 "L" (Wilmington) MY148179 "L" (Linden) LE207500 "L" (Linden) ME138400 Labor Operation Number: T1716 Labor Time: 0.9 Hour Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear Mount: > 912633 > Mar > 91 > Dash - Squeak/Squawk Noise on Turns Steering Gear Mount: All Technical Service Bulletins Dash - Squeak/Squawk Noise on Turns Number: 91-263-3 Section: 3 Date: MARCH 1991 Corp. Bulletin No.: 133201 Subject: NOISE FROM FRONT OF DASH WHEN TURNING Model and Year: 1990-91 CAVALIER, CORSICA, BERETTA Condition: Customers may comment about a squawk/creak noise from the front of dash when turning. They may also comment about a slight feeling of vague on-center steering and slow returnability. Cause: After a extended heat soak the grommet material starts to take a compression set. This set will lead to a rub condition between the gear and the grommet during steering. Correction: As part of trouble shooting, refer to Dealer Service Bulletin No. 90-409-3 for VIN breakpoints regarding the steering gear to front of dash clamp retaining nuts and inspect them. If the retaining nuts are not loose, it may be necessary to replace only the steering gear mounting grommets. If the retaining nuts are loose, it will be necessary to replace both the retaining nuts and steering gear mounting grommets. STEERING GEAR MOUNTING REPLACEMENT GROMMETS SUSPENSION RIGHT LEFT LEVEL PART NUMBER PART NUMBER FE1 26001492 7849985 FE2 26001492 26000626 FE3 26001492 26000626 FE7 (GTZ only) 26001492 26000626 Parts are currently available from GMSPO. Vehicles with possible grommet noise conditions were produced between breakpoints listed below: From the following serial From the start of 1991 number to the end of 1990 production to the production: following serial number: "J" (Lordstown) L7166829 "J" (Lordstown) M7164949 "J" (Janesville) U244293 "J" (Janesville) MJ174173 "L" (Wilmington) LY211048 "L" (Wilmington) MY148179 "L" (Linden) LE207500 "L" (Linden) ME138400 Labor Operation Number: T1716 Labor Time: 0.9 Hour Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair Steering Shaft Coupler: Service and Repair Fig. 16 Flange & Steering Coupling Assembly 1. Remove rack and pinion assembly from vehicle. 2. Remove pinch bolt from flange and steering coupling assembly, then coupling, Fig. 16. 3. Reverse procedure to install. Torque pinch bolt to 29 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Diagnostic Procedures Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4682 Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4683 condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4684 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4685 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4686 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4687 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 92503B > Nov > 91 > Steering Lead/Pull, Memory Steer/Unusual Tire Wear Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Diagnostic Procedures Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 92503B > Nov > 91 > Steering Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4693 Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 92503B > Nov > 91 > Steering Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4694 condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 92503B > Nov > 91 > Steering Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4695 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 92503B > Nov > 91 > Steering Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4696 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 92503B > Nov > 91 > Steering Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4697 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 92503B > Nov > 91 > Steering Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4698 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 4699 Steering Wheel: Service and Repair 1. Disconnect battery ground cable. 2. On Cavalier and Sunbird models, remove steering wheel center pad attaching screws. 3. Disconnect horn electrical connector, then remove steering wheel center pad. 4. On all models, remove steering wheel retaining nut and retainer. 5. Remove steering dampener, if equipped. 6. Scribe alignment marks on steering wheel and shaft to aid installation. 7. Using tool J-1859-03 or BT-61-9 or equivalent, remove steering wheel from shaft. 8. Reverse procedure to install. Torque steering wheel attaching nut to 30 ft. lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > Customer Interest: > 914173C > Sep > 91 > Inner Tie Rod Bushing - Creaking Noise Tie Rod Boot: Customer Interest Inner Tie Rod Bushing - Creaking Noise Number: 91-417-3C Section: 3C Date: SEPT. 1991 Corporate Bulletin No.: 133210 ASE No.: A4 Subject: INNER TIE ROD BUSHING CREAK Model and Year: 1990-91 CAVALIER, CORSICA, BERETTA Condition: Low ambient temperatures and moderate suspension travels may result in a creaking noise from the inner tie rod bushings. This noise is very similar and should not be confused with "stabilizer shaft bushing squawk." The "creak" occurs primarily at temperatures below 30 F and usually stops as the inner tie rods warm from engine heat. Lubing the inner tie rod assemblies with silicone grease may reduce the creak for a short time, but the noise will return. Cause: The creak is caused by the the rod bushing slipping inside of the tie rod end and is due to a change in bushing material that was found to be more sensitive to suspension travels during cold temperatures. Correction: Replace the tie rods with ones containing an improved bushing material using the procedure described in the appropriate Service Manual. For effective repair use all parts in kit, regardless of original condition. Part Number Description 26032209 Left Side inner tie-rod assembly kit 26032210 Right Side inner tie-rod assembly kit Parts are expected to be available on September 30, 1991. In case of limited inventory, parts will be placed on 400 Control to waive VIP surcharges. Only verifiable emergency VIP orders will be accepted. SPO will make every effort to obtain parts. However, the part will be shipped premium transportation at dealer's expense and all other order types will be placed on backorder until the 400 control is removed. VIN Breakpoints: 1991 vehicles built after the VIN breakpoints listed below contain the new inner tie rod bushing material. J-Car Lordstown M7263422 L-Car Wilmington MY220717 L-Car Linden ME170463 Labor Operation Number: Right E8040 Left E8041 Both E8047 Labor Time: Use Current Labor Time Guide Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 914173C > Sep > 91 > Inner Tie Rod Bushing - Creaking Noise Tie Rod Boot: All Technical Service Bulletins Inner Tie Rod Bushing - Creaking Noise Number: 91-417-3C Section: 3C Date: SEPT. 1991 Corporate Bulletin No.: 133210 ASE No.: A4 Subject: INNER TIE ROD BUSHING CREAK Model and Year: 1990-91 CAVALIER, CORSICA, BERETTA Condition: Low ambient temperatures and moderate suspension travels may result in a creaking noise from the inner tie rod bushings. This noise is very similar and should not be confused with "stabilizer shaft bushing squawk." The "creak" occurs primarily at temperatures below 30 F and usually stops as the inner tie rods warm from engine heat. Lubing the inner tie rod assemblies with silicone grease may reduce the creak for a short time, but the noise will return. Cause: The creak is caused by the the rod bushing slipping inside of the tie rod end and is due to a change in bushing material that was found to be more sensitive to suspension travels during cold temperatures. Correction: Replace the tie rods with ones containing an improved bushing material using the procedure described in the appropriate Service Manual. For effective repair use all parts in kit, regardless of original condition. Part Number Description 26032209 Left Side inner tie-rod assembly kit 26032210 Right Side inner tie-rod assembly kit Parts are expected to be available on September 30, 1991. In case of limited inventory, parts will be placed on 400 Control to waive VIP surcharges. Only verifiable emergency VIP orders will be accepted. SPO will make every effort to obtain parts. However, the part will be shipped premium transportation at dealer's expense and all other order types will be placed on backorder until the 400 control is removed. VIN Breakpoints: 1991 vehicles built after the VIN breakpoints listed below contain the new inner tie rod bushing material. J-Car Lordstown M7263422 L-Car Wilmington MY220717 L-Car Linden ME170463 Labor Operation Number: Right E8040 Left E8041 Both E8047 Labor Time: Use Current Labor Time Guide Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tie Rod Boot: > 649601 > Jan > 97 > Compact Disc Players CD Changer Loading Procedures Compact Disc Player (CD): All Technical Service Bulletins Compact Disc Players - CD Changer Loading Procedures File In Section: 9 - Accessories Bulletin No.: 64-96-01 Date: January, 1997 INFORMATION Subject: Compact Disc Players - Procedures for Correct Use and Maintenance Models: 1997 and Prior Passenger Cars and Trucks CD Changer Loading Procedures Because of differences in CD changer loading procedures, some confusion exists regarding this issue. Although correct loading procedures are included with each changer's Owner's Manual, often this information is not available to the dealer service personnel. Verify proper loading when evaluating customer concerns of "CD inoperative". Delco Electronics Product Type Loading Procedure Radio w/intergral CD label side up 6 disc changer (LLAI) label side up 10 disc changer (FMI) label side up 12 disc changer (LLAI) label side down Important: Failure to load magazine/player correctly will disable the operation. Important: Only the 12 disc changer is to be loaded with the label side down. CD Cleaners Avoid use of commercially available CD cleaners. The use of CD cleaners is not recommended and can damage the player's CD mechanism. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod Tie Rod End: Service and Repair Outer Tie Rod Fig. 11 Exploded View, Power Rack & Pinion Assembly. Front Wheel Fig. 11 Drive Beretta, Calais, Cavalier, Corsica, Grand Am, LeMans, Skyhawk, Skylark & Sunbird Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod > Page 4728 Fig. 12 Outer Tie Rod Assembly 1. Remove cotter pin, then hex slotted nut from outer tie rod ball stud, Fig. 11 and 12. 2. Loosen outer tie rod pinch bolts, then separate outer tie rod from steering knuckle using steering linkage puller, tool No. J 24319-01 or equivalent. 3. Remove outer tie rod from tie rod adjuster. 4. Reverse procedure to install, noting the following: a. On all models except LeMans, torque hex slotted nut to 35 ft. lbs., with a maximum of 50 ft. lbs. to install cotter pin. On LeMans models, torque nut to 44 ft. lbs,. with a maximum of 55 ft. lbs. to install cotter pin. b. Adjust toe by turning tie rod adjuster. c. Torque pinch bolts to 15 ft. lbs. on LeMans models and 41 ft. lbs. on all models except LeMans. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod > Page 4729 Tie Rod End: Service and Repair Inner Tie Rod Fig. 13 Inner Tie Rod Assembly 1. Remove and dispose of lock plate from inner tie rod bolts, Fig. 13. 2. Remove inner tie rod bolt. 3. Slide out and remove inner tie rod between bolt support plate and rack and pinion boot. If both inner tie rods are to be removed, after removing the first tie rod, reinstall bolt to keep rack and pinion and other parts aligned. 4. Reverse procedure to install. Ensure center housing cover washers are fitted into rack and pinion boot. Torque inner tie rod bolts to 65 ft. lbs. and install new lock plate with notches in proper position over flats of inner tie rod bolts. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection Ball Joint: Testing and Inspection 1. Raise and support vehicle so that suspension is allowed to hang free. 2. Grasp wheel and tire assembly at top and bottom, then rock top of wheel and tire assembly inward and outward. 3. While rocking wheel and tire assembly, observe movement between steering knuckle and control arm. If any horizontal movement is present, replace ball joint. 4. If ball joint is disconnected from steering knuckle, use finger to try to twist ball joint in its socket. If ball joint can be twisted in its socket, replace ball joint. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 4734 Ball Joint: Service and Repair Fig. 4. Control Arm Bushing Removal And Installation 1. Raise and support vehicle, then remove wheel and tire. 2. Install modified tool No. J 34754 or equivalent, then remove ball joint attaching cotter pin. 3. Remove ball joint stud retaining nut, then, using tool J-29330, on 1989-90 models, or J-38892, on 1991-92 models, separate ball joint from steering knuckle. 4. Using a 1/8 inch drill, drill pilot holes completely through the rivets. Using a 1/2 inch drill, drill final holes through rivets to ensure fitting of new ball joint. 5. Loosen stabilizer shaft assembly bushing attaching nut. 6. Remove ball joint from steering knuckle and control arm. 7. Assemble new ball joint to lower control arm with bolts provided in service package, Fig. 4. Torque bolts to specification. 8. Insert ball joint stud into steering knuckle and torque nut to specifications. 9. Install wheel and tire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair Control Arm Bushing: Service and Repair Fig. 4. Control Arm Bushing Removal And Installation 1. Raise rear of vehicle and support rear axle under front side of spring seat using a suitable jack. 2. Remove wheel and tire assembly. 3. If right hand side bushing is to be replaced, disconnect brake line bracket from body. If left hand side bushing is to be replaced, disconnect brake line bracket from frame and parking brake cable at hook guide. 4. Remove control arm to mounting bracket attaching nut, bolt and washer, then allow control arm to rotate downward. 5. The bushing can now be replaced using tools shown in Fig. 4. When installing bushing, the arrow on the installer must align with arrow on the receiver, Fig. 4. 6. Reverse procedure to complete installation. The control arm attaching bolt must be torqued after vehicle is lowered to floor and is in its standing height position. Torque attaching bolt to specifications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair 1. Raise and support vehicle, then remove wheel and tire. 2. Remove front hub and bearing as outlined under WHEEL BEARING procedure. 3. Using tool J-29330, on 1989-90 models or J-38892, on 1991-92 models, separate ball joint from steering knuckle. 4. Remove strut to steering knuckle attaching bolts, then disconnect strut from steering knuckle. 5. Assemble strut to new steering knuckle and install attaching bolts finger tight. 6. Insert ball joint stud into steering knuckle and torque stud nut to specification. 7. Torque strut to steering knuckle bolts to specification. 8. Reverse removal procedure to complete installation. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Shaft <--> [Stabilizer Bar, Sway Control] > Stabilizer Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Bushing: > 91423A3C > Feb > 92 > Suspension (Front) - Squawking/Clunking Noise Stabilizer Bushing: All Technical Service Bulletins Suspension (Front) - Squawking/Clunking Noise REVISED Number: 91-423A-3C Section: 3C Date: FEB. 1992 Corporate Bulletin No.: 133304R ASE No.: A4 Subject: SQUAWK/CLUNK NOISE FROM FRONT SUSPENSION Model and Year: 1985-91 CAVALIER 1987-91 CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 92-423-3C, DATED, SEPTEMBER 1991. THE LABOR OPERATION NUMBER HAS BEEN REVISED. ALL COPIES OF 91-423-3C SHOULD BE DISCARDED. CONDITION: Some 1985-91 J/L cars might exhibit a condition of a "Squawk" OR "Clunk" noise from the front suspension or engine compartment area when driving over small bumps or entering parking lots (i.e. washboard road surfaces, railroad tracks). CAUSE: The condition may be caused by the rubber bushing material bleeding through the teflon/polyester sock and coming into contact with the stabilizer bar. CORRECTION: If this condition is encountered, replace both stabilizer bar bushings with newer designed bushings. The part numbers for the new bushings are listed below: STABILIZER BAR DIAMETER BUSHING PART NUMBER(S) 22 mm 22566673 24 mm 22566674 26 mm 22566675 28 mm 22566676 30 mm 10088389 Parts are currently available from GMSPO. WARRANTY INFORMATION: Labor Operation Number: E2180 Labor Time: See Current Labor Time Guide TROUBLE CODE: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Shaft <--> [Stabilizer Bar, Sway Control] > Stabilizer Bushing > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Bushing: > 91423A3C > Feb > 92 > Suspension (Front) - Squawking/Clunking Noise Stabilizer Bushing: Customer Interest Suspension (Front) - Squawking/Clunking Noise REVISED Number: 91-423A-3C Section: 3C Date: FEB. 1992 Corporate Bulletin No.: 133304R ASE No.: A4 Subject: SQUAWK/CLUNK NOISE FROM FRONT SUSPENSION Model and Year: 1985-91 CAVALIER 1987-91 CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 92-423-3C, DATED, SEPTEMBER 1991. THE LABOR OPERATION NUMBER HAS BEEN REVISED. ALL COPIES OF 91-423-3C SHOULD BE DISCARDED. CONDITION: Some 1985-91 J/L cars might exhibit a condition of a "Squawk" OR "Clunk" noise from the front suspension or engine compartment area when driving over small bumps or entering parking lots (i.e. washboard road surfaces, railroad tracks). CAUSE: The condition may be caused by the rubber bushing material bleeding through the teflon/polyester sock and coming into contact with the stabilizer bar. CORRECTION: If this condition is encountered, replace both stabilizer bar bushings with newer designed bushings. The part numbers for the new bushings are listed below: STABILIZER BAR DIAMETER BUSHING PART NUMBER(S) 22 mm 22566673 24 mm 22566674 26 mm 22566675 28 mm 22566676 30 mm 10088389 Parts are currently available from GMSPO. WARRANTY INFORMATION: Labor Operation Number: E2180 Labor Time: See Current Labor Time Guide TROUBLE CODE: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Shaft <--> [Stabilizer Bar, Sway Control] > Stabilizer Bushing > Component Information > Technical Service Bulletins > Page 4756 Stabilizer Bushing: Service and Repair Fig. 6 Stabilizer Bar Installation 1. Raise and support vehicle, allowing control arms to hang freely. 2. Remove left front wheel and tire assembly. 3. Disconnect stabilizer bar at control arms and control arm supports. 4. Disconnect stabilizer bar from control arms, Fig. 6. 5. Loosen front and remove rear and center bolts from suspension support assembly. Lower support enough to allow stabilizer bar removal. 6. Remove stabilizer bar with insulators. 7. Reverse procedure to install. Torque suspension support assembly in a manner which will allow front suspension to hang free. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair Suspension Spring ( Coil / Leaf ): Service and Repair Fig. 2 Rear Suspension Exploded View Fig. 3 Coil Spring Installation Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Page 4760 1. Raise and support rear of vehicle. Support rear axle using a suitable jack. 2. Remove wheel and tire assemblies. 3. Remove brake line bracket attaching bolts from frame, Fig. 2, and allow brake lines to hang freely. 4. Remove shock absorber to lower mounting bracket bolts, then disconnect shock absorbers from axle assembly. Do not suspend rear axle by brake hoses since damage to hoses may result. 5. Carefully lower rear axle assembly and remove springs and insulators. 6. Reverse procedure to install. Position ends of upper coil in seat of body and within limits shown in Fig. 3. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 931683D > Apr > 93 > Shocks, Rear - Groan After Extended Vehicle Sitting Suspension Strut / Shock Absorber: Customer Interest Shocks, Rear - Groan After Extended Vehicle Sitting Number: 93-168-3D Section: 3D Date: APRIL 1993 Corporate Bulletin No.: 333402 ASE No.: A4 Subject: SHOCK GROAN ON 25 MM NON-GAS CHARGED REAR SHOCKS (REPLACE SHOCK ASSEMBLIES) Model and Year: 1991-93 CAVALIER, CORSICA AND BERETTA CONDITION: Some rear shocks may exhibit a groaning noise after the vehicle has been sitting stationary for an extended period of time. Shock groan usually disappears after driving the vehicle a short distance. This shock groan condition is sensitive to temperature and humidity. CAUSE: As the vehicles its stationary for an extended period of time, the oil film on the shock rod dries. When this occurs, the shock rod and seal interface is dry during the first several compressions/extensions. As the shock begins to become lubricated, this condition disappears. CORRECTION: Allow vehicle to sit idle overnight. Before driving or moving the vehicle, press down on the rear bumper. If a groan is detected, install two shock absorber assemblies. Replace shock assemblies with gas charged shocks (P/N 22064490). These shocks contain pre-lubricated seals which will not exhibit shock groan. Parts are expected to be available on May 3, 1993. Labor Operation Number: E-5807 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4774 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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: > 72-05-12 > Jan > 98 > Suspension - Shock Absorber/Strut Replacement Guidlines Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Replacement Guidlines File In Section: Warranty Administration Bulletin No.: 72-05-12 Date: January, 1998 WARRANTY ADMINISTRATION Subject: Replacement of Shock Absorbers and Struts Labor Operations E3800, E3801, E3807, E5800, E5801, E5807, E3850, E3851, E3857, E5750, E5751, and E5757 Models: All Past, Present, and Future Passenger Cars & Trucks The purpose of this bulletin is to provide retail and wholesale service personnel with enhanced service policies for the above listed subject labor operations. Service Management should make certain that all dealership personnel responsible for replacement of suspension components are familiar with GM Service Manual procedures. Effective with repair orders dated on or after January 15, 1998 the following must also be followed: - Shock absorber/strut assemblies are fluid filled components and will normally exhibit seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorber/strut assemblies are not to be replaced under warranty or seepage. - Defective shock absorber/strut assemblies will have a visible oil path or drip coming from the component. A visible oil path or drip coming from the shock absorber/strut assembly should be replaced as a defective component. - Only defective shock absorber/strut assemblies should be replaced. DO NOT replace pairs unless both are defective, unless otherwise instructed in the Service Manual and/or Service Bulletin. - Service Management approval is required on the repair order for replacement of struts or shocks in pairs. This approval includes noting the reason for replacement. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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: > 931683D > Apr > 93 > Shocks, Rear - Groan After Extended Vehicle Sitting Suspension Strut / Shock Absorber: All Technical Service Bulletins Shocks, Rear - Groan After Extended Vehicle Sitting Number: 93-168-3D Section: 3D Date: APRIL 1993 Corporate Bulletin No.: 333402 ASE No.: A4 Subject: SHOCK GROAN ON 25 MM NON-GAS CHARGED REAR SHOCKS (REPLACE SHOCK ASSEMBLIES) Model and Year: 1991-93 CAVALIER, CORSICA AND BERETTA CONDITION: Some rear shocks may exhibit a groaning noise after the vehicle has been sitting stationary for an extended period of time. Shock groan usually disappears after driving the vehicle a short distance. This shock groan condition is sensitive to temperature and humidity. CAUSE: As the vehicles its stationary for an extended period of time, the oil film on the shock rod dries. When this occurs, the shock rod and seal interface is dry during the first several compressions/extensions. As the shock begins to become lubricated, this condition disappears. CORRECTION: Allow vehicle to sit idle overnight. Before driving or moving the vehicle, press down on the rear bumper. If a groan is detected, install two shock absorber assemblies. Replace shock assemblies with gas charged shocks (P/N 22064490). These shocks contain pre-lubricated seals which will not exhibit shock groan. Parts are expected to be available on May 3, 1993. Labor Operation Number: E-5807 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4788 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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: > 72-05-12 > Jan > 98 > Suspension - Shock Absorber/Strut Replacement Guidlines Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Replacement Guidlines File In Section: Warranty Administration Bulletin No.: 72-05-12 Date: January, 1998 WARRANTY ADMINISTRATION Subject: Replacement of Shock Absorbers and Struts Labor Operations E3800, E3801, E3807, E5800, E5801, E5807, E3850, E3851, E3857, E5750, E5751, and E5757 Models: All Past, Present, and Future Passenger Cars & Trucks The purpose of this bulletin is to provide retail and wholesale service personnel with enhanced service policies for the above listed subject labor operations. Service Management should make certain that all dealership personnel responsible for replacement of suspension components are familiar with GM Service Manual procedures. Effective with repair orders dated on or after January 15, 1998 the following must also be followed: - Shock absorber/strut assemblies are fluid filled components and will normally exhibit seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorber/strut assemblies are not to be replaced under warranty or seepage. - Defective shock absorber/strut assemblies will have a visible oil path or drip coming from the component. A visible oil path or drip coming from the shock absorber/strut assembly should be replaced as a defective component. - Only defective shock absorber/strut assemblies should be replaced. DO NOT replace pairs unless both are defective, unless otherwise instructed in the Service Manual and/or Service Bulletin. - Service Management approval is required on the repair order for replacement of struts or shocks in pairs. This approval includes noting the reason for replacement. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replace Suspension Strut / Shock Absorber: Service and Repair Shock Absorber Replace Fig. 2 Rear Suspension Exploded View 1. Open deck lid, then remove trim cover and shock absorber upper retaining nut. 2. Raise rear of vehicle and support rear axle using a suitable jack. 3. Remove shock absorber lower attaching bolt, then disconnect shock absorber from mounting bracket, Fig. 2. Remove shock absorber from vehicle. 4. Reverse procedure to install. Torque attaching bolt to specification. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replace > Page 4795 Suspension Strut / Shock Absorber: Service and Repair Front Suspension Strut Removal/Installation Fig. 7 Installing Strut Assembly 1. Raise hood and remove strut protective cap and three strut to body attaching nuts. 2. Raise and support vehicle, support suspension using suitable jack stands. 3. Remove wheel and tire assembly, then install modified inner drive joint boot protector tool No. J-34754 4. On 1991-92 models, using tool J-24319, disconnect tie rod from strut assembly. 5. On all models, remove strut to steering knuckle attaching bolts, Fig. 7, then remove strut from vehicle. 6. Reverse procedure to install. Disassembly/Assembly Disassembly 1. Position strut compressor J-34013 in holding fixture J-3289-20. 2. Position strut in strut compressor, then compress strut approximately 1/2 of its height. Use care not to bottom spring or damper rod. 3. Remove nut from strut dampener shaft, then position guide rod J-34013-27 on dampener shaft. Use guide rod J-34013-27 to position dampener shaft down through bearing cap while compressing coil spring. 4. Remove components from coil strut unit. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replace > Page 4796 Fig. 8 Assembling Strut Unit Assembly 1. Position bearing cap on strut compressor. 2. Position strut to strut compressor and install compressor bottom locking pin. 3. Extend dampener shaft and install clamp J-34013-20 to hold shaft in position, Fig. 8. 4. Position spring over dampener, then position strut to strut compressor upper locking pin hole and install pin. 5. Install upper insulator, shield, bumper and upper spring seat. The flat on the upper spring seat should face in the same direction as the centerline of the strut assembly spindle, Fig. 8. 6. Install guide rod J-34013-27 onto dampener shaft, the compress strut unit until dampener shaft threads are visible. Remove guide rod and install retaining nut. 7. While holding dampener shaft in position with a suitable wrench, torque retaining nut to specification. After tightening nut, remove clamp from dampener shaft clamp J-34013-20. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing Removal and Installation Wheel Bearing: Service and Repair Front Wheel Bearing Removal and Installation FRONT WHEEL BEARINGS AND/OR HUB Fig. 2 Modified Outer Seal Protector Fig. 3 Removing And Installing Shaft Nut REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly, then install modified outer seal protector No. J 34754 or equivalent, Fig. 2. 3. Insert a drift punch through the rotor, Fig. 3, then remove axle shaft nut and washer. 4. On 1989-90 models, using a plastic or rubber mallet, strike end of axle shaft to disengage axle from hub and bearing. Shaft nut can be partially installed to protect threads. 5. On 1991-92 models, remove ball joint, then using tool No. J 28733-A or equivalent, disengage axle from hub and bearing assembly. 6. On all models, move axle shaft inward, then remove caliper attaching bolts and support caliper. 7. Remove brake rotor, then hub and bearing assembly attaching bolts. 8. Remove hub and bearing assembly. 9. Reverse to install. Torque attaching bolts to specifications. INSTALLATION 1. Install hub and bearing assembly, torque attaching bolts to specification. 2. Install hub and bearing seal, then the brake rotor. 3. Install caliper, torque attaching bolts to specification. 4. Move axle shaft outward, then insert drift punch through rotor, Fig. 3. 5. Install washer and new shaft nut, torque shaft nut to specification. 6. On 1991-92 models, install ball joint. 7. On all models, remove drift punch and seal protector. 8. Install tire and wheel assembly, then lower vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing Removal and Installation > Page 4801 Wheel Bearing: Service and Repair Rear Suspension REAR HUB AND/OR BEARINGS 1. Raise and support vehicle, then remove wheel and tire assembly and brake drum. Do not hammer brake drum since damage to bearing may result. 2. Remove four hub/bearing assembly to rear axle attaching bolts, then the hub/bearing assembly from axle. The upper rear hub attaching bolt may not clear brake shoe when removing hub and bearing assembly. Partially remove hub and bearing assembly prior to removing this bolt. 3. Reverse procedure to install. Torque hub attaching bolts to specification. Use care not to drop hub/bearing assembly since damage to bearing may result. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut Torque 183 - 192 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 931693E > Apr > 93 > Tires - Slipping on Rim Tires: Customer Interest Tires - Slipping on Rim Number: 93-169-3E Section: 3E Date: APRIL 1993 Corporate Bulletin No.: 393501 ASE No.: A4 Subject: TIRES SLIPPING ON WHEELS (USE PROPER TIRE MOUNTING PROCEDURE) Model and Year: 1988-93 ALL PASSENGER CARS AND LIGHT DUTY TRUCKS Some incidents of tires slipping (rotating) on wheels have been reported on 1988-93 passenger cars and light duty trucks. Most incidents have occurred when driven aggressively immediately after tire mounting. Hard acceleration and/or braking is usually required. This condition will affect wheel balance, which could result in a vibration. To reduce the chance of tires rotating on their wheels, any excess lube should be wiped from the tire and rim after tire mounting, but before inflating to seat the bead. (Never exceed 40 psi to seat the bead.) Also, the vehicle should not be driven aggressively for at least four hours after tire mounting to allow the lube to dry. GM Goodwrench Rubber Lubricant, p/n 12345884, is the recommended lube for tire mounting. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Diagnostic Procedures Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4819 Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4820 condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4821 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4822 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4823 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4824 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures Tires: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures > Page 4830 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures > Page 4831 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures > Page 4832 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures > Page 4833 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures > Page 4834 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05-03-10-020C > Apr > 10 > Wheels/Tires - Use of Nitrogen Gas in Tires Tires: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05-03-10-020C > Apr > 10 > Wheels/Tires - Use of Nitrogen Gas in Tires > Page 4839 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00-00-90-002J > Jan > 09 > Tires - Correct Inflation Pressure Information Tires: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00-00-90-002J > Jan > 09 > Tires - Correct Inflation Pressure Information > Page 4844 ^ 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 433502 > Jul > 94 > Tires - Speed Rated Information Tires: All Technical Service Bulletins Tires - Speed Rated Information Group Ref.: 3 - Steering/Suspension Bulletin No.: 433502 Date: July, 1994 INFORMATION SUBJECT: SPEED RATED TIRES MODELS: 1995 AND PRIOR YEAR PASSENGER CARS AND LIGHT DUTY TRUCKS All original equipment passenger car and light duty truck tires used by General Motors have a speed rating symbol molded on their sidewall. This speed symbol, along with the tire's load index, make up the service description that follows the tire's size. The original equipment tire size, speed rating, and recommended inflation pressure are listed on the tire placard usually located on the driver's door edge. WHEN REPLACING TIRES, NEVER INSTALL A TIRE THAT IS A SMALLER SIZE OR LESSER SPEED RATING THAN THAT USED AS ORIGINAL EQUIPMENT. As in the past, it is recommended that replacement tires have a TPC (Tire Performance Criteria) number on the sidewall that is identical to that on the original tires. Common speed rating on tires used by General Motors are as follows: (see illustration) IMPORTANT: Most base all season tires and touring tires used by GM are S rated. Performance tires will usually have a higher speed rating. High performance tires are usually Z rated. Z rated tires carry the Z symbol within the tire size, rather than after the size in the service description. These speeds apply only at the tire's full pressure. An underinflated tire will not meet its speed rating capability. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 323501 > Dec > 93 > Tires - Manufacturers' Assistance Tires: All Technical Service Bulletins Tires - Manufacturers' Assistance Group Ref.: Steering/ Suspension Bulletin No.: 323501 Date: December, 1993 INFORMATION SUBJECT: TIRE MANUFACTURERS' CONTACTS FOR ASSISTANCE MODELS: 1991-94 PASSENGER CARS AND TRUCKS General Tire has established a "Tire Fix" Department to assist you with anything from a tire adjustment to the location of the nearest General Tire dealer. "Tire Fix" representatives are available Monday through Friday from 8:00 A.M. to 6:00 P.M. Eastern Time at 1-800-847-3349. A General Tire Brochure is provided for review with all appropriate dealer personnel. A single contact point at General Tire can assist you with most aspects of their product to satisfy your customers' needs. Other tire manufacturers can be contacted for assistance at the Toll Free Numbers listed in illustration: Please retain this information for future reference. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 931693E > Apr > 93 > Tires - Slipping on Rim Tires: All Technical Service Bulletins Tires - Slipping on Rim Number: 93-169-3E Section: 3E Date: APRIL 1993 Corporate Bulletin No.: 393501 ASE No.: A4 Subject: TIRES SLIPPING ON WHEELS (USE PROPER TIRE MOUNTING PROCEDURE) Model and Year: 1988-93 ALL PASSENGER CARS AND LIGHT DUTY TRUCKS Some incidents of tires slipping (rotating) on wheels have been reported on 1988-93 passenger cars and light duty trucks. Most incidents have occurred when driven aggressively immediately after tire mounting. Hard acceleration and/or braking is usually required. This condition will affect wheel balance, which could result in a vibration. To reduce the chance of tires rotating on their wheels, any excess lube should be wiped from the tire and rim after tire mounting, but before inflating to seat the bead. (Never exceed 40 psi to seat the bead.) Also, the vehicle should not be driven aggressively for at least four hours after tire mounting to allow the lube to dry. GM Goodwrench Rubber Lubricant, p/n 12345884, is the recommended lube for tire mounting. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Technical Service Bulletin # 92503B Date: 911101 Steering - Lead/Pull, Memory Steer/Unusual Tire Wear Number: 92-50-3B Section: 3B Date: NOV. 1991 Corporate Bulletin No.: 073002R ASE No.: A4 Subject: LEAD/PULL, TORQUE/MEMORY STEER, STEERING WHEEL OFF CENTER Model and Year: 1982-92 CAVALIER, CORSICA AND BERETTA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-304-3B, DATED AUGUST 1990. THE 1992 MODEL YEAR HAS BEEN ADDED AS WELL AS CORRECTED INFORMATION LISTED IN STEPS 6 AND 7. ALL COPIES OF 90-304-3B SHOULD BE DISCARDED. The following diagnostic and repair information has been developed and compiled to assist dealer service personnel in their efforts to diagnose and correct vehicles exhibiting lead/pull, torque steer, memory steer, steering wheel off-center, and/or unusual tire wear conditions. A flow chart which will be helpful in understanding the logic of the diagnostic and repair procedures is included. DEFINITIONS Lead: On a smooth, flat road with the transaxle in neutral, the vehicle does not require a noticeable torque input to the steering wheel to maintain a straight path. However, with hands removed from the steering wheel, the vehicle drifts to the left or right. Pull: On a smooth, flat road with the transaxle in neutral, the vehicle requires a noticeable torque input to the steering wheel to maintain a straight path. A pull requires noticeable input to correct. Note: "Leads" and "pulls" are different terms for the same condition. Lead refers to the path deviation (usually a lane change in .2 miles or less); pull refers to the torque at the steering wheel required to maintain a straight path (more than .3 N-m or 2.7 lbs.in.). Torque Steer: On a smooth, flat road the vehicle has a left or right steering force that is eliminated when the transaxle is placed in neutral. The magnitude of the steering force is usually (but not always) dependent on the amount of applied engine torque. Torque steer at constant highway speed is frequently mistaken for leads/pulls. Memory Steer: On a smooth, flat road the vehicle exhibits a slight lead/pull condition when the vehicle is returned to a neutral or straight ahead position after completion of a turning maneuver. This condition is always noted as being in the same direction as the last turning maneuver (after a right turn, the vehicle leads or pulls to the right; after a left turn, the vehicle leads or pulls to the left), and may vary in degree right to left. This condition is most noticeable with the driver's hands off the steering wheel. Steering Wheel Angle: The "levelness" of the steering wheel when following a straight path. Steering wheel should appear to be level with the instrument panel when going straight ahead, and within +/- 5 degrees when measured on an alignment machine. Diagnostic Procedures Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4861 Step 1 Check Tires. A. Same size? B. Same brand? C. Equally worn? D. Abnormally worn or damaged? E. Same tire pressure (within 1 psi)? Record any problems noted in tire inspection. Step 2 PERFORM DIAGNOSTIC RIDE ON SMOOTH, FLAT (CROWN-FREE) ROAD. It is important to repeat road test in each direction to eliminate crosswind effects. Road crown and crosswind induced leads/pulls are normal. The following steps should be followed to properly identify the complaint Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4862 condition: A. Drive the vehicle on a straight, smooth, flat (crown-free) road surface at 40-60 mph (64 km/h to 97 km/h). Shift the transaxle to neutral and allow the vehicle to coast. Momentarily release the steering wheel and note if there is a change in direction in travel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDITION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A deviation from straight direction in neutral indicates a lead/pull. Proceed to lead/pull corrective action procedure. B. If no change in direction occurs in neutral, place the transaxle in drive and lightly accelerate from 40 mph to 60 mph while momentarily releasing the steering wheel. CAUTION: THE DRIVER'S HANDS SHOULD NOT BE MOVED FROM THE STEERING POSITION DURING THE MOMENTARY RELEASE OF THE STEERING WHEEL. IMPROPER VEHICLE CONDTION MIGHT CAUSE PATH DEVIATION. UNCORRECTED BY DRIVER STEERING, THIS MIGHT RESULT IN A COLLISION AND PERSONAL INJURY. A noticeable deviation from a straight path in drive indicates a torque steer. Proceed to torque steer corrective action procedure. C. With the vehicle stopped, steer left to full lock, then straighten wheel, but do not go past straight-ahead position. Lightly accelerate to 40 mph (64 km/h). Does the vehicle pull to the left throughout the acceleration? Repeat the procedure to the right. Does the vehicle now pull to the right? If the vehicle leads/pulls in the same direction as the last maneuver, the vehicle is exhibiting a "memory steer" condition. Another indication of "memory steer" is a noticeable difference in effort required for left-to-right vs right-to-left lock-to-lock turns while the vehicle is stopped. Proceed to memory steer corrective action procedure. D. If none of the above conditions exist, but the steering wheel is not "centered", proceed to steering wheel angle corrective action. Corrective Action Procedures Lead/Pull 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E0100. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle leads/pulls in the same direction, proceed to step 4. 3. Tire/wheel rotation for lead/pull. A. Swap LF tire/wheel with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Wheel alignment. Be sure alignment rack calibration is up to date. Note all before and after readings and record them on the repair order. This information will be requested if Technical Assistance is contacted, and will be helpful in Engineering analysis. A. Check camber and reset to nominal specification. B. Note, do not adjust caster settings. Caster cannot be adjusted. If caster is found to be out of specification, re-check on another machine, and verify calibration of current machine. If caster is still out of specification, see miscellaneous note # 4. If still out of specification, contact Technical Assistance so Engineering can be notified see "miscellaneous Note # 5 before calling T.A.S. 5. Re-ride vehicle. A. If vehicle is fixed, OK. Labor operation E2020. B. If vehicle pulls to left, proceed to step 6. C. If vehicle pulls to right, proceed to step 7. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4863 6. Reset camber for a lead/pull to the left. A. Set the RF camber to a "+" value (no more than + 1.00 degree). B. Set the LF camber to a "-" value (no more than - 1.00 degree). C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. 7. Reset camber for a lead/pull to the right. A. Set the RF camber to a "-" value (no more than - 1.00 degree). B. Set the LF camber to a "+" value (no more than + 1.00 degree), C. Total cross camber (left minus right) should be no more than 2 degrees. D. Re-ride. If not fixed, contact Technical Assistance. Torque Steer 1. Put vehicle on hoist. A. Visually inspect for damaged front and/or rear suspension or steering components. B. Check for obvious brake drag. C. Swap left front tire/wheel assembly with right front tire/wheel assembly. Cross only the front tires/wheels. Do not perform a standard or modified "X" rotation. 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. B. If the vehicle torque steers in the opposite direction from the original complaint, the problem is most likely to be tire related. Proceed to step 3. C. If the vehicle torque steers in the same direction, proceed to step 4. 3. Tire/wheel rotation for torque steer. A. Swap LF tire/wheel assembly with LR tire/wheel and re-ride. B. If vehicle is fixed, replace LR tire (tire that was originally on RF). If vehicle is not fixed replace RF tire (tire that was originally on LF.) C. Re-ride to confirm fix. Labor operations E0100 and E0420. 4. Measure front suspension "Z" heights as specified in Service Manual. One method of taking this measurement is to stretch a string tightly between the grease fittings on the bottom of the ball joints and measure the distance up from the string to the bottom surface of the suspension support. If the side-to-side difference is greater than 6 mm (1/4 inch), correct the "Z" heights to equal settings. "Z" height can be increased by installing a new service replacement spring that is one part number "stronger" (or more if required) than the original equipment spring. Each subsequent spring code will result in approximately 8 mm (3/8 inch) difference in "Z" height from the previous code. 5. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3020 or E3021. B. If the vehicle still torque steers, proceed to next step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4864 Figure 1 6. Measure transaxle heights-see Figure 1. Side-to-side transaxle heights should be equal. If side-to-side differences are greater than 6 mm (1/4 inch), follow the engine shake-down procedure below: A. Loosen the engine/transaxle to body mounts. B. Start the vehicle and shift from reverse to drive slowly three times to re-settle the engine/transaxle assembly. Figure 2 C. Block vehicle wheels and apply park and service brakes. With an assistant watching the engine, make sure the transmission mount is not grounded against the stop in drive. If so, shift the mount until the rubber stop is not contacting the mount with the engine in drive. Refer to Figure 2. (1992 "J" car only). D. Re-tighten all engine and transaxle mounts to body. E. Check to see if the engine/transaxle is not level by measuring as described above. If it is not level, shim engine/transaxle mounts to raise the side with the lowest reading, using appropriate wheel alignment shim stock. Labor operation T4639. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4865 7. Re-ride the vehicle A. If the vehicle is fixed, OK. B. If the vehicle still torque steers, contact Technical Assistance. Memory Steer 1. Replace upper strut mount/bearing assemblies following procedure in Service Manual. See "Miscellaneous notes # 9." 2. Re-ride the vehicle. A. If the vehicle is fixed, OK. Labor operation E3927. B. If the vehicle still exhibits memory steer, the steering gear may have high friction and should be replaced. See miscellaneous notes # 9. Labor operation E9730. Steering Wheel Angle Not "Centered" Reset toe-in with steering wheel locked in "centered" position. Confirm that steering wheel is straight. Labor operation E2000. Other Corrective Action Procedures Check ball joints for binding or sticking by raising the vehicle on a hoist, and disconnect the tie rods. Move the tires back and forth and feel for any binding or sticking. If any is felt, the ball joint(s) may need to be replaced. Miscellaneous Notes 1. Poor alignment will not cause vibration complaints. 2. Toe-in does not affect leads/pulls or torque steer. It only affects steering wheel angle and tire wear. 3. Camber and caster values should not change during vehicle shipment. 4. Some caster adjustments may be made using the following procedure, which utilizes available tolerance in fastener holes. Do not file or elongate any body sheet metal. A. Loosen the 6 suspension support bolts on the side needing adjustment. B. Using a pry bar or other appropriate tool, adjust the suspension support forward to increase caster, or rearward to decrease caster. C. Tighten the 6 suspension support bolts while holding the suspension support in the desired position. D. Loosen the 3 strut mount fasteners in the engine compartment and move the top of the strut rearward to increase caster or forward to decrease caster. 5. Never modify body sheet metal to adjust caster or camber on J/N/L vehicles. There is not enough structure or inside spring clearance to do so. 6. Always confirm calibration of alignment machine before calling Technical Assistance. 7. Try a known good set of tires on a continual problem vehicle before calling Technical Assistance. This will rule out tires as a cause of the problem. 8. If it is necessary to call Technical Assistance, please have the following information ready to give to the Technical Assistance Engineer: A. Nature of complaint - What the customer complained about, mileage, and whether it is a torque steer, lead/pull, memory steer, or steering wheel off center. B. Last calibration date of alignment rack, type of equipment and model number. C. Tire size and brand, and condition of tires. D. Before and after alignment readings. E. "Z" heights. F. Call only after attached procedure(s) has been performed. 9. For vehicles still under warranty, please use correct labor operation codes for what has been done, and keep records (before/after measurements, customer concern, etc). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 92503B > Nov > 91 > Steering - Lead/Pull, Memory Steer/Unusual Tire Wear > Page 4866 E0100 is the labor operation number used for warranty claims for front tire swaps because of lead/pull or torque steer concerns. E2020 is the labor operation number used for warranty claims for toe adjust. Correct repair is to reset front wheel individual and sum toe while locking the steering wheel in correct level position. Do not use E2020 to claim a toe adjust. Remember that a toe adjust will not correct torque steer or leads/pulls; it only corrects excessive tire wear and steering wheel angle. 10. Do not claim an alignment labor operation in addition to another labor operation that requires (and includes labor time for) an alignment. The labor time for the alignment is either included in the labor operation or will be added to the labor operation. A good example of this is a strut replacement. The times for a camber check should be added, but an E2020 should not be claimed in addition to the strut change code. 11. Whenever possible in unusual or difficult-to-resolve cases, keep all defective parts and information for possible Engineering analysis. This includes defective tires, steering gears, strut mounts, and any other involved parts. 12. Whenever possible, record before and after measurements of caster, camber, toe, and suspension "Z" heights. This will speed up the resolution of these problems. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 911713E > Jan > 91 > Tire - Tread Chunking/Torn bead Tires: All Technical Service Bulletins Tire - Tread Chunking/Torn bead Number: 91-171-3E Section: 3E Date: January 1991 Corp. Bulletin No.: 993501R Subject: TIRE DAMAGE CAUSED IN GM ASSEMBLY PLANTS - TREAD CHUNKING TORN BEAD Model and Year: 1988-91 PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-52-3E, DATED OCTOBER 1989. THE 1991 MODEL YEAR HAS BEEN ADDED. ALL COPIES OF 90-52-3E SHOULD BE DISCARDED. Isolated incidents of the following types of tire damage have recently been reported from the field. Any such damage would be present at time of delivery to the dealer. The probable cause of some of this damage has been traced to the assembly plant. Since such tire conditions are usually not the fault of the tire manufacturer, any tires requiring replacement for these reasons should be considered GM's responsibility. Assembly plant damage should not be confused with transportation damage, which continues to be the responsibility of the transportation company. The purpose of this bulletin is to help identify assembly plant tire damage. Tread Chunking This condition is identified by small pieces of tread rubber torn or "chunked" out of the tire. This usually occurs in one area of the tread, although more than one area is possible. The missing tread rubber should be apparent upon visual inspection. It can also usually be detected as a once-per-rev tire noise upon road testing. This condition can happen in the assembly plant during the end of line line roll test. Hard braking such that the tire locks up on the roll could be the cause, although other variables during the roll test can also be factors. Other types of tire tread damage noted at delivery should be considered transportation damage. Torn Bead Rubber This condition is usually not visible unless the tire is dismounted from the wheel and, therefore, may not be detected during new vehicle inspection. Depending on the extent of the tear, the condition may later be detected as a slow air loss, or a slight sidewall bulge. If the tire is dismounted from the wheel and bead rubber is torn, it is possible that this damage occurred in the assembly plant during tire mounting. If it happened in the plant, the tear will usually be on the inboard (blackwall) side of the tire. There should also be evidence of two tears, about 90 degrees apart, although one is usually much Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 911713E > Jan > 91 > Tire - Tread Chunking/Torn bead > Page 4871 more apparent than the other. Both the above described conditions occur very infrequently, with ongoing enhancements underway to reduce their occurance even further. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures Tires: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures > Page 4877 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures > Page 4878 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures > Page 4879 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures > Page 4880 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair Procedures > Page 4881 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05-03-10-020C > Apr > 10 > Wheels/Tires - Use of Nitrogen Gas in Tires Tires: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05-03-10-020C > Apr > 10 > Wheels/Tires - Use of Nitrogen Gas in Tires > Page 4886 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00-00-90-002J > Jan > 09 > Tires - Correct Inflation Pressure Information Tires: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00-00-90-002J > Jan > 09 > Tires - Correct Inflation Pressure Information > Page 4891 ^ 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 433502 > Jul > 94 > Tires - Speed Rated Information Tires: All Technical Service Bulletins Tires - Speed Rated Information Group Ref.: 3 - Steering/Suspension Bulletin No.: 433502 Date: July, 1994 INFORMATION SUBJECT: SPEED RATED TIRES MODELS: 1995 AND PRIOR YEAR PASSENGER CARS AND LIGHT DUTY TRUCKS All original equipment passenger car and light duty truck tires used by General Motors have a speed rating symbol molded on their sidewall. This speed symbol, along with the tire's load index, make up the service description that follows the tire's size. The original equipment tire size, speed rating, and recommended inflation pressure are listed on the tire placard usually located on the driver's door edge. WHEN REPLACING TIRES, NEVER INSTALL A TIRE THAT IS A SMALLER SIZE OR LESSER SPEED RATING THAN THAT USED AS ORIGINAL EQUIPMENT. As in the past, it is recommended that replacement tires have a TPC (Tire Performance Criteria) number on the sidewall that is identical to that on the original tires. Common speed rating on tires used by General Motors are as follows: (see illustration) IMPORTANT: Most base all season tires and touring tires used by GM are S rated. Performance tires will usually have a higher speed rating. High performance tires are usually Z rated. Z rated tires carry the Z symbol within the tire size, rather than after the size in the service description. These speeds apply only at the tire's full pressure. An underinflated tire will not meet its speed rating capability. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 323501 > Dec > 93 > Tires - Manufacturers' Assistance Tires: All Technical Service Bulletins Tires - Manufacturers' Assistance Group Ref.: Steering/ Suspension Bulletin No.: 323501 Date: December, 1993 INFORMATION SUBJECT: TIRE MANUFACTURERS' CONTACTS FOR ASSISTANCE MODELS: 1991-94 PASSENGER CARS AND TRUCKS General Tire has established a "Tire Fix" Department to assist you with anything from a tire adjustment to the location of the nearest General Tire dealer. "Tire Fix" representatives are available Monday through Friday from 8:00 A.M. to 6:00 P.M. Eastern Time at 1-800-847-3349. A General Tire Brochure is provided for review with all appropriate dealer personnel. A single contact point at General Tire can assist you with most aspects of their product to satisfy your customers' needs. Other tire manufacturers can be contacted for assistance at the Toll Free Numbers listed in illustration: Please retain this information for future reference. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 911713E > Jan > 91 > Tire - Tread Chunking/Torn bead Tires: All Technical Service Bulletins Tire - Tread Chunking/Torn bead Number: 91-171-3E Section: 3E Date: January 1991 Corp. Bulletin No.: 993501R Subject: TIRE DAMAGE CAUSED IN GM ASSEMBLY PLANTS - TREAD CHUNKING TORN BEAD Model and Year: 1988-91 PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-52-3E, DATED OCTOBER 1989. THE 1991 MODEL YEAR HAS BEEN ADDED. ALL COPIES OF 90-52-3E SHOULD BE DISCARDED. Isolated incidents of the following types of tire damage have recently been reported from the field. Any such damage would be present at time of delivery to the dealer. The probable cause of some of this damage has been traced to the assembly plant. Since such tire conditions are usually not the fault of the tire manufacturer, any tires requiring replacement for these reasons should be considered GM's responsibility. Assembly plant damage should not be confused with transportation damage, which continues to be the responsibility of the transportation company. The purpose of this bulletin is to help identify assembly plant tire damage. Tread Chunking This condition is identified by small pieces of tread rubber torn or "chunked" out of the tire. This usually occurs in one area of the tread, although more than one area is possible. The missing tread rubber should be apparent upon visual inspection. It can also usually be detected as a once-per-rev tire noise upon road testing. This condition can happen in the assembly plant during the end of line line roll test. Hard braking such that the tire locks up on the roll could be the cause, although other variables during the roll test can also be factors. Other types of tire tread damage noted at delivery should be considered transportation damage. Torn Bead Rubber This condition is usually not visible unless the tire is dismounted from the wheel and, therefore, may not be detected during new vehicle inspection. Depending on the extent of the tear, the condition may later be detected as a slow air loss, or a slight sidewall bulge. If the tire is dismounted from the wheel and bead rubber is torn, it is possible that this damage occurred in the assembly plant during tire mounting. If it happened in the plant, the tear will usually be on the inboard (blackwall) side of the tire. There should also be evidence of two tears, about 90 degrees apart, although one is usually much Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 911713E > Jan > 91 > Tire - Tread Chunking/Torn bead > Page 4904 more apparent than the other. Both the above described conditions occur very infrequently, with ongoing enhancements underway to reduce their occurance even further. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4913 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4914 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4915 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4920 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 931693E > Apr > 93 > Tires - Slipping on Rim Wheels: Customer Interest Tires - Slipping on Rim Number: 93-169-3E Section: 3E Date: APRIL 1993 Corporate Bulletin No.: 393501 ASE No.: A4 Subject: TIRES SLIPPING ON WHEELS (USE PROPER TIRE MOUNTING PROCEDURE) Model and Year: 1988-93 ALL PASSENGER CARS AND LIGHT DUTY TRUCKS Some incidents of tires slipping (rotating) on wheels have been reported on 1988-93 passenger cars and light duty trucks. Most incidents have occurred when driven aggressively immediately after tire mounting. Hard acceleration and/or braking is usually required. This condition will affect wheel balance, which could result in a vibration. To reduce the chance of tires rotating on their wheels, any excess lube should be wiped from the tire and rim after tire mounting, but before inflating to seat the bead. (Never exceed 40 psi to seat the bead.) Also, the vehicle should not be driven aggressively for at least four hours after tire mounting to allow the lube to dry. GM Goodwrench Rubber Lubricant, p/n 12345884, is the recommended lube for tire mounting. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4930 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4931 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4932 *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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4937 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4942 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4943 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4948 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4949 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4950 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 4955 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-03-10-102 > Jun > 99 > Warranty - OE Chrome Plated Aluminum Wheel ID Wheels: All Technical Service Bulletins Warranty - OE Chrome Plated Aluminum Wheel ID File In Section: 03 - Suspension Bulletin No.: 99-03-10-102 Date: June, 1999 INFORMATION Subject: Original Equipment Chrome Plated Aluminum Wheel Identification Models: 1999 and Prior Passenger Cars and Light Duty Trucks Chrome plated aluminum wheels have been returned to the Warranty Parts Center that are not the original equipment (OE) components. Original equipment chrome plated aluminum wheels can be identified by either a balance weight clip retention groove (1) or a step (2) that is machined around both of the wheel's rim flanges. The rim flanges (3) of painted original equipment aluminum wheels do not have a groove or a step. Chrome plated aluminum wheels that do not have the wheel rim flange groove or step are aftermarket chrome plated components and are NOT warrantable. Any aftermarket chrome wheels received by the Warranty Parts Center will be charged back to the dealership. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 72-05-05 > Aug > 97 > Warranty - Guidelines for Using E0420 Wheel Replace Wheels: All Technical Service Bulletins Warranty - Guidelines for Using E0420 Wheel Replace File In Section: Warranty Administration Bulletin No.: 72-05-05 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Using EO42O Wheel Replace Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide service personnel with guidelines for using the above subject labor operation. Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Aluminum Wheels (including chrome plated) with Porosity - Wheels that exhibit porosity should be repaired as described in the vehicle service manual. Wheels should not be replaced without wholesale approval. ^ Aluminum Wheels (except chrome plated) with a "Finish Defect" - Wheels that exhibit a defect in the finish, (i.e., discoloration or surface degradation) should be refinished as described in the Corporate Service Bulletin Number 53-17-03A released in May, 1996. ^ Chrome Wheels - Wheels that are chromed and found to have a finish defect can only be replaced. ^ Aluminum and chrome wheels replaced under warranty will be subject to random part review and inspection. Those wheels inspected and found not to be defective and/or should have been repaired, will be subject to charge back. Wheels damaged by normal wear, road hazards, car wash brushes, or other physical or chemical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 531703A > May > 96 > Aluminum Wheels Refinishing Technical Service Bulletin # 531703A Date: 960501 Aluminum Wheels - Refinishing File In Section: 10 - Body Bulletin No.: 53-17-03A Date: May, 1996 INFORMATION Subject: Aluminum Wheel Refinishing Models: 1991-96 Passenger Cars and Trucks This bulletin is being revised to delete the 1990 model year and add the 1996 model year. Please discard Corporate Bulletin Number 53-17-03 (Section 10 - Body). This bulletin supersedes and cancels all previous service bulletins concerning the refinishing of aluminum wheels. The purpose of this service bulletin is to assist dealerships in repairing the discoloration or surface degradation that has occurred on styled aluminum wheels. This bulletin provides NEW PROCEDURES AND SPECIFIC MATERIALS for the refinishing of painted aluminum wheels or aluminum wheels with discoloration or surface degradation. Important: THE RE-MACHINING OF ALUMINUM WHEELS IS NOT RECOMMENDED. THE RE-CLEAR COATING OF ALUMINUM WHEELS IS NO LONGER RECOMMENDED DUE TO CONCERNS OF REPAIR DURABILITY The new procedure requires the wheel surface be plastic media blasted to remove old paint or clear coat. CHEMICAL STRIPPERS ARE NOT RECOMMENDED. Material Required System 1: DuPont Products 3939-S Cleaning Solvent 615/616 Etching Primer URO 5000 Primer Surfacer IMRON 6000 Basecoat 3440-S IMRON Clear System 2: PPG Products DX533 Aluminum Cleaner DX503 Aluminum Conditioner DP Epoxy Primer Deltron Basecoat (DBC) Concept 2001 Clear Acrylic Urethane System 3: Spies Hecker Permahyd Silicone Remover 7090 Permahyd 1:1 Primer 4070 Permahyd 2:1 Surfacer 5080 Permahyd Base Coat Series 280/285 Permahyd H.S. Clearcoat 8060 Color Selection If the wheels being painted were previously clearcoated aluminum, we would recommend using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option to the customer, you may also use body color. For color Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 531703A > May > 96 > Aluminum Wheels Refinishing > Page 4972 selection and verification, refer to your paint manufacturer's color book. On wheels that were previous clearcoated aluminum it is recommended that all four wheels and their center caps be refinished to maintain color uniformity. Important: THE PRODUCTS LISTED MUST BE USED AS A SYSTEM. DO NOT MIX OTHER MANUFACTURERS' PRODUCT LINES WITH THE REQUIRED MATERIALS. PRODUCTS LISTED IN THIS BULLETIN HAVE SHOWN THE REQUIRED REPAIR DURABILITY, AND CURRENTLY ARE THE ONLY PAINT SYSTEMS THAT MEET GM SPECIFICATION 4350M-A336. Procedures 1. Remove wheels from vehicle. Tires may remain mounted on wheels. 2. Remove balance weights and mark their location on tire. 3. Wipe excess grease, etc. from wheels with wax and grease remover. 4. Have wheels plastic media blasted to remove clearcoat. FOR FURTHER INFORMATION ON MEDIA BLASTING IN YOUR AREA, CALL US TECHNOLOGIES INC., CONTACT DAVE ROSENBURG AT 1-800-634-9185. Caution: IT IS MANDATORY THAT ADEQUATE RESPIRATORY PROTECTION BE WORN. EXAMPLES OF SUCH PROTECTION ARE: AIR LINE RESPIRATORS WITH FULL HOOD OR HALF MASK. IF NOT AVAILABLE, USE A VAPOR/PARTICULATE RESPIRATOR THAT RESPIRATOR MANUFACTURER RECOMMENDS AS EFFECTIVE FOR ISOCYANATE VAPOR AND MISTS (UNLESS LOCAL REGULATIONS PREVAIL). 5. Painting Process a. Refer to Attachments 1-3 for each System's individual formula and process. b. After following the specific System's individual formula and process, follow these steps: 6. Unmask wheels. 7. Clean all wheel mounting surface of any corrosion, overspray, or dirt. 8. Install new coated balance weights, at marked locations. 9. Replace wheels on vehicle. 10. USE A TORQUE STICK ON AN IMPACT WRENCH, OR A TORQUE WRENCH TO CONSISTENTLY AND UNIFORMLY FASTEN THE WHEEL TO THE SPECIFIED TORQUE FOR THE VEHICLE. THE STAR PATTERN MUST BE FOLLOWED. Important: TORQUE STICKS MUST BE USED ANY TIME AN IMPACT WRENCH IS USED TO TIGHTEN WHEEL NUTS. Warranty Information For vehicles repaired under warranty, use as shown. Attachment 1 - DuPont Products Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 531703A > May > 96 > Aluminum Wheels Refinishing > Page 4973 Painting Process System: Dupont Products Paint Color Information: Corsican Silver WA EQ9283 Dupont # C9143, Sparkle Silver WA9967 Dupont # C9339 1. Wipe wheel with cleaning solvent: 3939-S, 3949-S or 3900-S. 2. Mask off tires. Important: 3. Mask off all wheel mounting surfaces and wheel mount surfaces. 4. Apply two coats of 615/616-S etching primer to wheel allowing 10 minutes flash between coats. Allow to dry for 30 minutes before applying primer coat. 5. Apply URO 5000 primer 1220/193-S + accelerator 389-S using two coats at 65-70 PSI at the gun. Allow 12-15 minutes between coats. Force bake 30 minutes at 140°F (60°C). 6. Scuff sand using green Scotch-Brite pad. 7. Solvent wipe before top coating. 8. Apply IMRON 6000 base coat to wheel. 2-3 coats to hiding at 60-70 PSI allowing to flash between coats. Base coat needs to dry 20-30 minutes before clearcoat is applied. 9. Apply 3440-S clearcoat to wheel using two coats at 60-70 PSI. Flash 10-15 minutes between coats. 389-S can be used in basecoat and clearcoat to give faster set up times. 10. Allow overnight dry before reassemble. Can be baked for 30 minutes at 140°F (60°C). Attachment 2 - PPG Products Painting Process: PPG System Paint Color Information: Corsican Silver WAEQ9283; PPG # DBC-3531, Sparkle Silver WA9967; PPG # 35367 1. Wash entire wheel with aluminum cleaner DX533, mix 1:3 with water. Allow to react 2-3 minutes and rinse thoroughly. 2. Wash entire wheel with aluminum conditioner DX5O3 straight from the container. Allow to react 2-3 minutes until pale gold or tan color develops. Rinse thoroughly and dry. 3. Mask off tires. Important: 4. Mask off all wheel nut mounting surfaces and wheel mounting surfaces. 5. Apply 1-2 coats of DP Primer and allow to flash for 15-20 minutes. 6. Apply 2-3 coats of Deltron Basecoat (DBC) and allow to flash 20 minutes after the final coat. 7. Apply two (2) wet coats of Concept 2001 Acrylic urethane. 8. Flash 20 minutes and bake 140°F (60°C) for 30 minutes. For more information contact your PPG Jobber. Attachment 3 - Spies Hecker Painting Process: Spies Hecker System Paint Color Information: Corsican Silver AWEQ9283; SH-72913, Sparkle Silver WA9967; SH-71912 1. Clean with Permahyd Silicone Remover 7090. 2. Mask off tires. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 531703A > May > 96 > Aluminum Wheels Refinishing > Page 4974 Important: 3. Mask off all wheel nut mounting surfaces and wheel mounting surfaces. 4. Apply 1-1/2 coats of Permahyd 1:1 Primer 4070. Mix 1:1 with Permahyd Hardener 3070 as per TDS. 5. Allow to flash for 30 minutes. 6. Apply two (2) coats of Permahyd 2:1 Surfacer 5080. Mix 2:1 with Permahyd Hardener 3071 as per TDS. 7. Bake for 60 minutes at 140°F (60°C) or allow to flash for 3 hours at 68°F (20°C). 8. Apply Permahyd Base Coat Series 280/285 as per TDS. 9. Allow to flash 10 to 15 minutes. 10. Apply 1 to 2 coats of Permacron High Solid Clear Coat 8060 as per TDS. 11. Allow to flash 10 minutes. Then bake at 140°F (60°C) for 40 minutes. For more information, contact your SPIES HECKER Jobber. 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 or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 393504 > Jul > 93 > Wheels - Sealing Leaking Cast Aluminum Wheels: All Technical Service Bulletins Wheels - Sealing Leaking Cast Aluminum Bulletin Number: 93-3-16 Reference Number: 393504 Publish Date: 7/93 Subject: LEAKING CAST ALUMINUM WHEELS (REPAIR WITH ADHESIVE SEALANT) Models Affected: 1985-1993 ALL MODELS Should a vehicle equipped with cast aluminum wheels exhibit a slow leak due to a porous condition existing in the wheel, the wheel can be repaired by using Dow Corning Silastic 732 RTV, p/n 1052366 or equivalent, as described in the following procedure: 1. Remove tire-wheel assembly from vehicle. 2. Locate leaking area by inflating tire to 40 psi and dipping tire-wheel assembly in water bath. 3. If air bubbles are observed, mark leak area and remove tire from wheel. 4. Scuff INSIDE rim surface at leak area with # 80 grit paper and clean area with general purpose cleaner, such as 3M # 08984. 5. Apply 1/8" thick layer of adhesive/sealant to leak area on INSIDE of rim and allow six hours of drying time. 6. Mount tire on wheel, pressurizing to 40 psi and check for leaks. NOTICE: Caution must be used when mounting the tire so as not to damage the sealer. 7. Adjust tire pressure to meet placard specification. 8. Balance tire-wheel assembly, using proper coated weights. 9. Water test wheel again. 10. Reinstall tire-wheel assembly on vehicle. Parts are currently available from GMSPO. WARRANTY INFORMATION: Labor Operation Number: E0420 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 931693E > Apr > 93 > Tires - Slipping on Rim Wheels: All Technical Service Bulletins Tires - Slipping on Rim Number: 93-169-3E Section: 3E Date: APRIL 1993 Corporate Bulletin No.: 393501 ASE No.: A4 Subject: TIRES SLIPPING ON WHEELS (USE PROPER TIRE MOUNTING PROCEDURE) Model and Year: 1988-93 ALL PASSENGER CARS AND LIGHT DUTY TRUCKS Some incidents of tires slipping (rotating) on wheels have been reported on 1988-93 passenger cars and light duty trucks. Most incidents have occurred when driven aggressively immediately after tire mounting. Hard acceleration and/or braking is usually required. This condition will affect wheel balance, which could result in a vibration. To reduce the chance of tires rotating on their wheels, any excess lube should be wiped from the tire and rim after tire mounting, but before inflating to seat the bead. (Never exceed 40 psi to seat the bead.) Also, the vehicle should not be driven aggressively for at least four hours after tire mounting to allow the lube to dry. GM Goodwrench Rubber Lubricant, p/n 12345884, is the recommended lube for tire mounting. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 93203E > Oct > 92 > Aluminum Wheels Scuff/Scratch Removal Wheels: All Technical Service Bulletins Aluminum Wheels - Scuff/Scratch Removal Number: 93-20-3E Section: 3E Date: OCT. 1992 Corporate Bulletin No.: 010103R ASE No.: A3 Subject: PROCEDURES ON SCUFF/SCRATCH REMOVAL FROM CLEAR COAT ON ALUMINUM WHEELS Model and Year: 1981-85 CITATION 1982-93 CAVALIER 1985-88 MONTE CARLO 1985-90 CELEBRITY 1981-93 CAPRICE, CAMARO AND CORVETTE 1990-93 LUMINA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-321 -3E, DATED AUGUST 1990. THE 1991 -93 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 90-321 -3E SHOULD BE DISCARDED. The clear coat on aluminum wheels can become scuffed and dull if the car is exposed to frequent automatic car washes with aggressive tire brushes. Following are procedures for polishing out minor scuffs and scratches from the clear coat on aluminum wheels. Outlined are three basic procedures which progress from least aggressive (A) to most aggressive (C) depending on the degree of scuffs or scratches in the clear coat. A. Condition - Minor surface scuffs and scratches. Procedure: 1. Clean the wheel surface with soap and water and dry thoroughly. 2. Clean the wheel with 3M general purpose adhesive cleaner, P/N 08984, or equivalent and dry 3. Apply 3M finesse-it finishing material, P/N 05928, or equivalent to the affected area and polish using a 3M superbuff polishing pad, P/N 05705, or equivalent on a low speed polisher (1500-2300 rpm's). 4. Begin with firm pressure on the polisher in the beginning and gradually reduce pressure as the finishing material begins to dry up. 5. Apply a coat of 3M liquid polish, P/N 05939 or 05993, or equivalent to protect the clear coat. B. Condition - More significant scuffs and dulling not removed during procedure A. Procedure: 1. Perform steps 1 and 2 from procedure A. 2. Apply 3M imperial microfinishing compound, P/N 06011, or equivalent and buff with a 3M superbuff compounding pad, P/N 05701, or equivalent on a low speed polisher. A second application may be necessary. 3. Inspect wheel finish. If scuffs and dulling have been removed, proceed to step 4; if not, proceed to procedure C. 4. Finish polishing the wheel with 3M finesse-it finishing material, P/N 05928, or equivalent and a superbuff polishing pad, P/N 05705, or equivalent on a low speed buffer. 5. Apply a coat of 3M liquid polish, P/N O5939 or O5993, or equivalent to protect clear coat. C. Condition - Very significant dulling, scratches, scuffs which have not penetrated through the clear coat. 1. Clean wheel with soap and water and dry. 2. Clean with 3M general purpose adhesive cleaner, P/N 08984, or equivalent. 3. Wet sand the affected area with 3M imperial wet-or-dry paper grade 1500 on a #20 sponge pad, P/N 05526, or equivalent. 4. Occasionally squeegee away the water and check progress. Stop sanding when an even dull appearance is reached. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 93203E > Oct > 92 > Aluminum Wheels Scuff/Scratch Removal > Page 4987 5. Polish the clear coat to a high gloss using 3M finesse-it finishing material, P/N 05928, or equivalent with a 3M superbuff polishing pad, P/N 05705, or equivalent on a low speed polisher (1500-2300 rpm's). 6. Apply a coat of 3M liquid polish, P/N 05939 or 05993, or equivalent to protect clear coat. NOTE: The following tips will result in an improved appearance when polishing or buffing. ^ Begin with firm pressure and reduce pressure as the polish or compound begins to dry. ^ Do not polish with a dry pad. Use enough material to keep the surface wet. ^ Use extreme caution when polishing or buffing sharp corners or contours to avoid burning the clear coat. Hand rubbing may be necessary. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting Wheels: All Technical Service Bulletins Wheels (Steel) - Damage Due to Improper Mounting Number: 92-232-3E Section: 3E Date: JUNE 1992 Corporate Bulletin No.: 233002 ASE No.: A4 Subject: AVOIDING DAMAGE TO STEEL WHEELS FROM IMPROPER WHEEL/TIRE CHANGING TECHNIQUES Model and Year: 1983-92 ALL PASSENGER CARS AND TRUCKS WITH STEEL WHEELS It is important to use proper procedures to prevent damage to either the tire mounting surface or the wheel mounting holes. Damage can result from the improper wheel attachment or tire mounting techniques on vehicles with steel wheels. 1. IMPROPER TIRE CHANGING TECHNIQUES: It takes about 70 seconds for the air to completely exhaust from a large tire. If the technician doesn't wait this amount of time after removing the valve core, the bead breaker on the tire change could put enough force on the tire to bend the wheel at the mounting surface. Such damage can result in vibration, shimmy, and under severe usage (i.e. police vehicle) lead to cracking. 2. OVER TORQUING OF THE WHEEL NUTS: The service specification for wheel nuts is listed in the Service Manuals. Some wheels have been observed with wheel nuts that were over torqued by as much as 50 percent. This may damage the wheel mounting holes and may also lead to cracks. I. PROPER TIRE CHANGING TECHNIQUES: Completely deflate the tire before attempting to break the tire bead loose. MOUNTING SURFACE CHECKING PROCEDURE Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 4992 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 4993 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 4994 A. Obtain a straight edge approximately 8-9 inches long and, while holding it in two hands, as shown in the attached illustration, place it on the inboard mounting surface of the wheel and try to rock it up and down. B. Repeat the above procedure on three or four different positions on the wheel inboard mounting surface. C. The outer ring of the mounting surface is normally raised above everything inside it. If a wheel mounting surface has been bent on a tire changer, it will be raised above the outer ring and the straight edge will rock on this "raised" portion. D. If a bent wheel is found, it must be replaced. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 4995 II. OVER TORQUING OF WHEEL NUTS: 1. A TORQUE WRENCH MUST BE USED to insure that the wheel nuts are tightened to specification. This should be done in two steps using the star pattern. First, snug the nuts down by hand. Then, using the star pattern and a torque wrench, tighten the wheel nuts to about half the final torque. Finally, tighten the wheel nuts to specification using the star pattern and a torque wrench. 2. NEVER use lubricants or penetrating fluids on wheel studs, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 91353E > Aug > 90 > Aluminum Wheels - New Coated Wheel Weights Wheels: All Technical Service Bulletins Aluminum Wheels - New Coated Wheel Weights Number: 91-35-3E Section: 3E Date: August 1990 Corporate Bulletin No.: 003502 Subject: COATED WHEEL WEIGHTS FOR ALUMINUM WHEELS Model and Year: 1985-91 MODELS WITH CAST ALUMINUM WHEELS TO: ALL CHEVROLET DEALERS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 89-65-3E, DATED JANUARY 1989. POLYESTER COATED WHEEL WEIGHTS NOW AVAILABLE FROM GMSPO. THE 1990-91 MODEL YEARS HAVE ALSO BEEN ADDED. ALL COPIES OF 89-65-3E SHOULD BE DISCARDED. Vehicles with cast aluminum wheels use a coated clip on wheel weight. The coating has recently changed from nylon to polyester, giving a more natural appearance that more closely matches the wheel. Coated balance weights are used on both the inboard and outboard rim flanges. They will not discolor, corrode or damage the appearance of the wheel as may have been the case in the past with uncoated clip on weights. These coated weights will fit most GM cast aluminum wheels. There are two types of coated wheel weights available to fit the GM vehicles (see illustration). Both types of weights are available from GMSPO in 1/4 ounce increments. See usage chart below to determine which type weight is correct for the vehicle. "MC" Type Weight Used On: 1990-1991 "W" Car 1988-1990 "Y" Car "AW" Type Weight 1989-1991 "L" Car Used On All Other 1991 "B" Car, "U" Van Series Vehicles 1/4 oz. P/N 9591670 P/N 9591669 1/2 oz. 9591584 9591582 3/4 oz. 9591585 9591583 1-1/4 oz. 9591378 9591362 1-1/2 oz. 9591379 9591363 1-3/4 oz. 9591380 9591364 2 oz. 9591381 9591365 "MC" Type Weight Used On: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 91353E > Aug > 90 > Aluminum Wheels - New Coated Wheel Weights > Page 5000 1990-1991 "W" Car 1988-1990 "Y" Car "AW" Type Weight 1989-1991 "L" Car Used On All Other 1991 "B" Car, "U" Van Series Vehicles 2-1/4 oz. 9591382 9591366 2-1/2 oz. 9591383 9591367 3oz. 9591385 9591369 Parts are currently available from GMSPO. Dealers should make sure they have a supply of both types weights for balancing GM aluminum wheels. When installing the coated weights, care must be taken so that the coating does not crack. It is recommended that a Teflon tipped hammer be used, such as 85403 Nicholson Industrial Hammer, their part number CAS 3340551, available through the Charles Strelinger Company, Warren, Mi (313-268-4100), or equivalent. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5006 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5007 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5008 *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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5013 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5018 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5019 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-03-10-102 > Jun > 99 > Warranty - OE Chrome Plated Aluminum Wheel ID Wheels: All Technical Service Bulletins Warranty - OE Chrome Plated Aluminum Wheel ID File In Section: 03 - Suspension Bulletin No.: 99-03-10-102 Date: June, 1999 INFORMATION Subject: Original Equipment Chrome Plated Aluminum Wheel Identification Models: 1999 and Prior Passenger Cars and Light Duty Trucks Chrome plated aluminum wheels have been returned to the Warranty Parts Center that are not the original equipment (OE) components. Original equipment chrome plated aluminum wheels can be identified by either a balance weight clip retention groove (1) or a step (2) that is machined around both of the wheel's rim flanges. The rim flanges (3) of painted original equipment aluminum wheels do not have a groove or a step. Chrome plated aluminum wheels that do not have the wheel rim flange groove or step are aftermarket chrome plated components and are NOT warrantable. Any aftermarket chrome wheels received by the Warranty Parts Center will be charged back to the dealership. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 72-05-05 > Aug > 97 > Warranty - Guidelines for Using E0420 Wheel Replace Wheels: All Technical Service Bulletins Warranty - Guidelines for Using E0420 Wheel Replace File In Section: Warranty Administration Bulletin No.: 72-05-05 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Using EO42O Wheel Replace Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide service personnel with guidelines for using the above subject labor operation. Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Aluminum Wheels (including chrome plated) with Porosity - Wheels that exhibit porosity should be repaired as described in the vehicle service manual. Wheels should not be replaced without wholesale approval. ^ Aluminum Wheels (except chrome plated) with a "Finish Defect" - Wheels that exhibit a defect in the finish, (i.e., discoloration or surface degradation) should be refinished as described in the Corporate Service Bulletin Number 53-17-03A released in May, 1996. ^ Chrome Wheels - Wheels that are chromed and found to have a finish defect can only be replaced. ^ Aluminum and chrome wheels replaced under warranty will be subject to random part review and inspection. Those wheels inspected and found not to be defective and/or should have been repaired, will be subject to charge back. Wheels damaged by normal wear, road hazards, car wash brushes, or other physical or chemical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 531703A > May > 96 > Aluminum Wheels Refinishing Technical Service Bulletin # 531703A Date: 960501 Aluminum Wheels - Refinishing File In Section: 10 - Body Bulletin No.: 53-17-03A Date: May, 1996 INFORMATION Subject: Aluminum Wheel Refinishing Models: 1991-96 Passenger Cars and Trucks This bulletin is being revised to delete the 1990 model year and add the 1996 model year. Please discard Corporate Bulletin Number 53-17-03 (Section 10 - Body). This bulletin supersedes and cancels all previous service bulletins concerning the refinishing of aluminum wheels. The purpose of this service bulletin is to assist dealerships in repairing the discoloration or surface degradation that has occurred on styled aluminum wheels. This bulletin provides NEW PROCEDURES AND SPECIFIC MATERIALS for the refinishing of painted aluminum wheels or aluminum wheels with discoloration or surface degradation. Important: THE RE-MACHINING OF ALUMINUM WHEELS IS NOT RECOMMENDED. THE RE-CLEAR COATING OF ALUMINUM WHEELS IS NO LONGER RECOMMENDED DUE TO CONCERNS OF REPAIR DURABILITY The new procedure requires the wheel surface be plastic media blasted to remove old paint or clear coat. CHEMICAL STRIPPERS ARE NOT RECOMMENDED. Material Required System 1: DuPont Products 3939-S Cleaning Solvent 615/616 Etching Primer URO 5000 Primer Surfacer IMRON 6000 Basecoat 3440-S IMRON Clear System 2: PPG Products DX533 Aluminum Cleaner DX503 Aluminum Conditioner DP Epoxy Primer Deltron Basecoat (DBC) Concept 2001 Clear Acrylic Urethane System 3: Spies Hecker Permahyd Silicone Remover 7090 Permahyd 1:1 Primer 4070 Permahyd 2:1 Surfacer 5080 Permahyd Base Coat Series 280/285 Permahyd H.S. Clearcoat 8060 Color Selection If the wheels being painted were previously clearcoated aluminum, we would recommend using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option to the customer, you may also use body color. For color Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 531703A > May > 96 > Aluminum Wheels Refinishing > Page 5036 selection and verification, refer to your paint manufacturer's color book. On wheels that were previous clearcoated aluminum it is recommended that all four wheels and their center caps be refinished to maintain color uniformity. Important: THE PRODUCTS LISTED MUST BE USED AS A SYSTEM. DO NOT MIX OTHER MANUFACTURERS' PRODUCT LINES WITH THE REQUIRED MATERIALS. PRODUCTS LISTED IN THIS BULLETIN HAVE SHOWN THE REQUIRED REPAIR DURABILITY, AND CURRENTLY ARE THE ONLY PAINT SYSTEMS THAT MEET GM SPECIFICATION 4350M-A336. Procedures 1. Remove wheels from vehicle. Tires may remain mounted on wheels. 2. Remove balance weights and mark their location on tire. 3. Wipe excess grease, etc. from wheels with wax and grease remover. 4. Have wheels plastic media blasted to remove clearcoat. FOR FURTHER INFORMATION ON MEDIA BLASTING IN YOUR AREA, CALL US TECHNOLOGIES INC., CONTACT DAVE ROSENBURG AT 1-800-634-9185. Caution: IT IS MANDATORY THAT ADEQUATE RESPIRATORY PROTECTION BE WORN. EXAMPLES OF SUCH PROTECTION ARE: AIR LINE RESPIRATORS WITH FULL HOOD OR HALF MASK. IF NOT AVAILABLE, USE A VAPOR/PARTICULATE RESPIRATOR THAT RESPIRATOR MANUFACTURER RECOMMENDS AS EFFECTIVE FOR ISOCYANATE VAPOR AND MISTS (UNLESS LOCAL REGULATIONS PREVAIL). 5. Painting Process a. Refer to Attachments 1-3 for each System's individual formula and process. b. After following the specific System's individual formula and process, follow these steps: 6. Unmask wheels. 7. Clean all wheel mounting surface of any corrosion, overspray, or dirt. 8. Install new coated balance weights, at marked locations. 9. Replace wheels on vehicle. 10. USE A TORQUE STICK ON AN IMPACT WRENCH, OR A TORQUE WRENCH TO CONSISTENTLY AND UNIFORMLY FASTEN THE WHEEL TO THE SPECIFIED TORQUE FOR THE VEHICLE. THE STAR PATTERN MUST BE FOLLOWED. Important: TORQUE STICKS MUST BE USED ANY TIME AN IMPACT WRENCH IS USED TO TIGHTEN WHEEL NUTS. Warranty Information For vehicles repaired under warranty, use as shown. Attachment 1 - DuPont Products Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 531703A > May > 96 > Aluminum Wheels Refinishing > Page 5037 Painting Process System: Dupont Products Paint Color Information: Corsican Silver WA EQ9283 Dupont # C9143, Sparkle Silver WA9967 Dupont # C9339 1. Wipe wheel with cleaning solvent: 3939-S, 3949-S or 3900-S. 2. Mask off tires. Important: 3. Mask off all wheel mounting surfaces and wheel mount surfaces. 4. Apply two coats of 615/616-S etching primer to wheel allowing 10 minutes flash between coats. Allow to dry for 30 minutes before applying primer coat. 5. Apply URO 5000 primer 1220/193-S + accelerator 389-S using two coats at 65-70 PSI at the gun. Allow 12-15 minutes between coats. Force bake 30 minutes at 140°F (60°C). 6. Scuff sand using green Scotch-Brite pad. 7. Solvent wipe before top coating. 8. Apply IMRON 6000 base coat to wheel. 2-3 coats to hiding at 60-70 PSI allowing to flash between coats. Base coat needs to dry 20-30 minutes before clearcoat is applied. 9. Apply 3440-S clearcoat to wheel using two coats at 60-70 PSI. Flash 10-15 minutes between coats. 389-S can be used in basecoat and clearcoat to give faster set up times. 10. Allow overnight dry before reassemble. Can be baked for 30 minutes at 140°F (60°C). Attachment 2 - PPG Products Painting Process: PPG System Paint Color Information: Corsican Silver WAEQ9283; PPG # DBC-3531, Sparkle Silver WA9967; PPG # 35367 1. Wash entire wheel with aluminum cleaner DX533, mix 1:3 with water. Allow to react 2-3 minutes and rinse thoroughly. 2. Wash entire wheel with aluminum conditioner DX5O3 straight from the container. Allow to react 2-3 minutes until pale gold or tan color develops. Rinse thoroughly and dry. 3. Mask off tires. Important: 4. Mask off all wheel nut mounting surfaces and wheel mounting surfaces. 5. Apply 1-2 coats of DP Primer and allow to flash for 15-20 minutes. 6. Apply 2-3 coats of Deltron Basecoat (DBC) and allow to flash 20 minutes after the final coat. 7. Apply two (2) wet coats of Concept 2001 Acrylic urethane. 8. Flash 20 minutes and bake 140°F (60°C) for 30 minutes. For more information contact your PPG Jobber. Attachment 3 - Spies Hecker Painting Process: Spies Hecker System Paint Color Information: Corsican Silver AWEQ9283; SH-72913, Sparkle Silver WA9967; SH-71912 1. Clean with Permahyd Silicone Remover 7090. 2. Mask off tires. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 531703A > May > 96 > Aluminum Wheels Refinishing > Page 5038 Important: 3. Mask off all wheel nut mounting surfaces and wheel mounting surfaces. 4. Apply 1-1/2 coats of Permahyd 1:1 Primer 4070. Mix 1:1 with Permahyd Hardener 3070 as per TDS. 5. Allow to flash for 30 minutes. 6. Apply two (2) coats of Permahyd 2:1 Surfacer 5080. Mix 2:1 with Permahyd Hardener 3071 as per TDS. 7. Bake for 60 minutes at 140°F (60°C) or allow to flash for 3 hours at 68°F (20°C). 8. Apply Permahyd Base Coat Series 280/285 as per TDS. 9. Allow to flash 10 to 15 minutes. 10. Apply 1 to 2 coats of Permacron High Solid Clear Coat 8060 as per TDS. 11. Allow to flash 10 minutes. Then bake at 140°F (60°C) for 40 minutes. For more information, contact your SPIES HECKER Jobber. 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 or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 393504 > Jul > 93 > Wheels - Sealing Leaking Cast Aluminum Wheels: All Technical Service Bulletins Wheels - Sealing Leaking Cast Aluminum Bulletin Number: 93-3-16 Reference Number: 393504 Publish Date: 7/93 Subject: LEAKING CAST ALUMINUM WHEELS (REPAIR WITH ADHESIVE SEALANT) Models Affected: 1985-1993 ALL MODELS Should a vehicle equipped with cast aluminum wheels exhibit a slow leak due to a porous condition existing in the wheel, the wheel can be repaired by using Dow Corning Silastic 732 RTV, p/n 1052366 or equivalent, as described in the following procedure: 1. Remove tire-wheel assembly from vehicle. 2. Locate leaking area by inflating tire to 40 psi and dipping tire-wheel assembly in water bath. 3. If air bubbles are observed, mark leak area and remove tire from wheel. 4. Scuff INSIDE rim surface at leak area with # 80 grit paper and clean area with general purpose cleaner, such as 3M # 08984. 5. Apply 1/8" thick layer of adhesive/sealant to leak area on INSIDE of rim and allow six hours of drying time. 6. Mount tire on wheel, pressurizing to 40 psi and check for leaks. NOTICE: Caution must be used when mounting the tire so as not to damage the sealer. 7. Adjust tire pressure to meet placard specification. 8. Balance tire-wheel assembly, using proper coated weights. 9. Water test wheel again. 10. Reinstall tire-wheel assembly on vehicle. Parts are currently available from GMSPO. WARRANTY INFORMATION: Labor Operation Number: E0420 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 93203E > Oct > 92 > Aluminum Wheels Scuff/Scratch Removal Wheels: All Technical Service Bulletins Aluminum Wheels - Scuff/Scratch Removal Number: 93-20-3E Section: 3E Date: OCT. 1992 Corporate Bulletin No.: 010103R ASE No.: A3 Subject: PROCEDURES ON SCUFF/SCRATCH REMOVAL FROM CLEAR COAT ON ALUMINUM WHEELS Model and Year: 1981-85 CITATION 1982-93 CAVALIER 1985-88 MONTE CARLO 1985-90 CELEBRITY 1981-93 CAPRICE, CAMARO AND CORVETTE 1990-93 LUMINA THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 90-321 -3E, DATED AUGUST 1990. THE 1991 -93 MODEL YEARS HAVE BEEN ADDED. ALL COPIES OF 90-321 -3E SHOULD BE DISCARDED. The clear coat on aluminum wheels can become scuffed and dull if the car is exposed to frequent automatic car washes with aggressive tire brushes. Following are procedures for polishing out minor scuffs and scratches from the clear coat on aluminum wheels. Outlined are three basic procedures which progress from least aggressive (A) to most aggressive (C) depending on the degree of scuffs or scratches in the clear coat. A. Condition - Minor surface scuffs and scratches. Procedure: 1. Clean the wheel surface with soap and water and dry thoroughly. 2. Clean the wheel with 3M general purpose adhesive cleaner, P/N 08984, or equivalent and dry 3. Apply 3M finesse-it finishing material, P/N 05928, or equivalent to the affected area and polish using a 3M superbuff polishing pad, P/N 05705, or equivalent on a low speed polisher (1500-2300 rpm's). 4. Begin with firm pressure on the polisher in the beginning and gradually reduce pressure as the finishing material begins to dry up. 5. Apply a coat of 3M liquid polish, P/N 05939 or 05993, or equivalent to protect the clear coat. B. Condition - More significant scuffs and dulling not removed during procedure A. Procedure: 1. Perform steps 1 and 2 from procedure A. 2. Apply 3M imperial microfinishing compound, P/N 06011, or equivalent and buff with a 3M superbuff compounding pad, P/N 05701, or equivalent on a low speed polisher. A second application may be necessary. 3. Inspect wheel finish. If scuffs and dulling have been removed, proceed to step 4; if not, proceed to procedure C. 4. Finish polishing the wheel with 3M finesse-it finishing material, P/N 05928, or equivalent and a superbuff polishing pad, P/N 05705, or equivalent on a low speed buffer. 5. Apply a coat of 3M liquid polish, P/N O5939 or O5993, or equivalent to protect clear coat. C. Condition - Very significant dulling, scratches, scuffs which have not penetrated through the clear coat. 1. Clean wheel with soap and water and dry. 2. Clean with 3M general purpose adhesive cleaner, P/N 08984, or equivalent. 3. Wet sand the affected area with 3M imperial wet-or-dry paper grade 1500 on a #20 sponge pad, P/N 05526, or equivalent. 4. Occasionally squeegee away the water and check progress. Stop sanding when an even dull appearance is reached. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 93203E > Oct > 92 > Aluminum Wheels Scuff/Scratch Removal > Page 5047 5. Polish the clear coat to a high gloss using 3M finesse-it finishing material, P/N 05928, or equivalent with a 3M superbuff polishing pad, P/N 05705, or equivalent on a low speed polisher (1500-2300 rpm's). 6. Apply a coat of 3M liquid polish, P/N 05939 or 05993, or equivalent to protect clear coat. NOTE: The following tips will result in an improved appearance when polishing or buffing. ^ Begin with firm pressure and reduce pressure as the polish or compound begins to dry. ^ Do not polish with a dry pad. Use enough material to keep the surface wet. ^ Use extreme caution when polishing or buffing sharp corners or contours to avoid burning the clear coat. Hand rubbing may be necessary. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting Wheels: All Technical Service Bulletins Wheels (Steel) - Damage Due to Improper Mounting Number: 92-232-3E Section: 3E Date: JUNE 1992 Corporate Bulletin No.: 233002 ASE No.: A4 Subject: AVOIDING DAMAGE TO STEEL WHEELS FROM IMPROPER WHEEL/TIRE CHANGING TECHNIQUES Model and Year: 1983-92 ALL PASSENGER CARS AND TRUCKS WITH STEEL WHEELS It is important to use proper procedures to prevent damage to either the tire mounting surface or the wheel mounting holes. Damage can result from the improper wheel attachment or tire mounting techniques on vehicles with steel wheels. 1. IMPROPER TIRE CHANGING TECHNIQUES: It takes about 70 seconds for the air to completely exhaust from a large tire. If the technician doesn't wait this amount of time after removing the valve core, the bead breaker on the tire change could put enough force on the tire to bend the wheel at the mounting surface. Such damage can result in vibration, shimmy, and under severe usage (i.e. police vehicle) lead to cracking. 2. OVER TORQUING OF THE WHEEL NUTS: The service specification for wheel nuts is listed in the Service Manuals. Some wheels have been observed with wheel nuts that were over torqued by as much as 50 percent. This may damage the wheel mounting holes and may also lead to cracks. I. PROPER TIRE CHANGING TECHNIQUES: Completely deflate the tire before attempting to break the tire bead loose. MOUNTING SURFACE CHECKING PROCEDURE Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 5052 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 5053 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 5054 A. Obtain a straight edge approximately 8-9 inches long and, while holding it in two hands, as shown in the attached illustration, place it on the inboard mounting surface of the wheel and try to rock it up and down. B. Repeat the above procedure on three or four different positions on the wheel inboard mounting surface. C. The outer ring of the mounting surface is normally raised above everything inside it. If a wheel mounting surface has been bent on a tire changer, it will be raised above the outer ring and the straight edge will rock on this "raised" portion. D. If a bent wheel is found, it must be replaced. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 922323E > Jun > 92 > Wheels (Steel) - Damage Due to Improper Mounting > Page 5055 II. OVER TORQUING OF WHEEL NUTS: 1. A TORQUE WRENCH MUST BE USED to insure that the wheel nuts are tightened to specification. This should be done in two steps using the star pattern. First, snug the nuts down by hand. Then, using the star pattern and a torque wrench, tighten the wheel nuts to about half the final torque. Finally, tighten the wheel nuts to specification using the star pattern and a torque wrench. 2. NEVER use lubricants or penetrating fluids on wheel studs, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 91353E > Aug > 90 > Aluminum Wheels - New Coated Wheel Weights Wheels: All Technical Service Bulletins Aluminum Wheels - New Coated Wheel Weights Number: 91-35-3E Section: 3E Date: August 1990 Corporate Bulletin No.: 003502 Subject: COATED WHEEL WEIGHTS FOR ALUMINUM WHEELS Model and Year: 1985-91 MODELS WITH CAST ALUMINUM WHEELS TO: ALL CHEVROLET DEALERS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 89-65-3E, DATED JANUARY 1989. POLYESTER COATED WHEEL WEIGHTS NOW AVAILABLE FROM GMSPO. THE 1990-91 MODEL YEARS HAVE ALSO BEEN ADDED. ALL COPIES OF 89-65-3E SHOULD BE DISCARDED. Vehicles with cast aluminum wheels use a coated clip on wheel weight. The coating has recently changed from nylon to polyester, giving a more natural appearance that more closely matches the wheel. Coated balance weights are used on both the inboard and outboard rim flanges. They will not discolor, corrode or damage the appearance of the wheel as may have been the case in the past with uncoated clip on weights. These coated weights will fit most GM cast aluminum wheels. There are two types of coated wheel weights available to fit the GM vehicles (see illustration). Both types of weights are available from GMSPO in 1/4 ounce increments. See usage chart below to determine which type weight is correct for the vehicle. "MC" Type Weight Used On: 1990-1991 "W" Car 1988-1990 "Y" Car "AW" Type Weight 1989-1991 "L" Car Used On All Other 1991 "B" Car, "U" Van Series Vehicles 1/4 oz. P/N 9591670 P/N 9591669 1/2 oz. 9591584 9591582 3/4 oz. 9591585 9591583 1-1/4 oz. 9591378 9591362 1-1/2 oz. 9591379 9591363 1-3/4 oz. 9591380 9591364 2 oz. 9591381 9591365 "MC" Type Weight Used On: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 91353E > Aug > 90 > Aluminum Wheels - New Coated Wheel Weights > Page 5060 1990-1991 "W" Car 1988-1990 "Y" Car "AW" Type Weight 1989-1991 "L" Car Used On All Other 1991 "B" Car, "U" Van Series Vehicles 2-1/4 oz. 9591382 9591366 2-1/2 oz. 9591383 9591367 3oz. 9591385 9591369 Parts are currently available from GMSPO. Dealers should make sure they have a supply of both types weights for balancing GM aluminum wheels. When installing the coated weights, care must be taken so that the coating does not crack. It is recommended that a Teflon tipped hammer be used, such as 85403 Nicholson Industrial Hammer, their part number CAS 3340551, available through the Charles Strelinger Company, Warren, Mi (313-268-4100), or equivalent. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing Removal and Installation Wheel Bearing: Service and Repair Front Wheel Bearing Removal and Installation FRONT WHEEL BEARINGS AND/OR HUB Fig. 2 Modified Outer Seal Protector Fig. 3 Removing And Installing Shaft Nut REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly, then install modified outer seal protector No. J 34754 or equivalent, Fig. 2. 3. Insert a drift punch through the rotor, Fig. 3, then remove axle shaft nut and washer. 4. On 1989-90 models, using a plastic or rubber mallet, strike end of axle shaft to disengage axle from hub and bearing. Shaft nut can be partially installed to protect threads. 5. On 1991-92 models, remove ball joint, then using tool No. J 28733-A or equivalent, disengage axle from hub and bearing assembly. 6. On all models, move axle shaft inward, then remove caliper attaching bolts and support caliper. 7. Remove brake rotor, then hub and bearing assembly attaching bolts. 8. Remove hub and bearing assembly. 9. Reverse to install. Torque attaching bolts to specifications. INSTALLATION 1. Install hub and bearing assembly, torque attaching bolts to specification. 2. Install hub and bearing seal, then the brake rotor. 3. Install caliper, torque attaching bolts to specification. 4. Move axle shaft outward, then insert drift punch through rotor, Fig. 3. 5. Install washer and new shaft nut, torque shaft nut to specification. 6. On 1991-92 models, install ball joint. 7. On all models, remove drift punch and seal protector. 8. Install tire and wheel assembly, then lower vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing Removal and Installation > Page 5065 Wheel Bearing: Service and Repair Rear Suspension REAR HUB AND/OR BEARINGS 1. Raise and support vehicle, then remove wheel and tire assembly and brake drum. Do not hammer brake drum since damage to bearing may result. 2. Remove four hub/bearing assembly to rear axle attaching bolts, then the hub/bearing assembly from axle. The upper rear hub attaching bolt may not clear brake shoe when removing hub and bearing assembly. Partially remove hub and bearing assembly prior to removing this bolt. 3. Reverse procedure to install. Torque hub attaching bolts to specification. Use care not to drop hub/bearing assembly since damage to bearing may result. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 914143E > Sep > 91 > Wheel Center Caps - Rattling Noise Wheel Cover: Customer Interest Wheel Center Caps - Rattling Noise Number: 91-414-3E Section: 3E Date: SEPT. 1991 Corporate Bulletin No.: 133503 ASE No.: A2, A3, A4, A5, B1 Subject: RATTLE NOISE AS A RESULT OF LOOSE WHEEL CENTER CAPS Model and Year: 1991 CAVALIER WITH Z24 TRIM PACKAGE Condition: Some 1991 "J" cars with the Z24 trim package may exhibit a rattling noise due to the wheel center hub cap being loose. Cause: Loose fit between the wheel and wheel center cap caused by oversize diameter in wheel. Correction: Using channel-lock pliers, with a cloth on cap face to protect the disc from damage, rework the center cap wire retaining ring (as shown in the picture) in five places to provide a tight fit of the cap to the improperly machined wheels. Bend the wire ring toward the cap disc as shown to obtain a permanent set of approximately one (1) wire diameter. This condition effects all 1991 Chevrolet J cars with Z24 from 1991 start of production through VIN breakpoint M7194096. Labor Operation Number: T1761 Labor Time: 0.2 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 914143E > Sep > 91 > Wheel Center Caps - Rattling Noise > Page 5074 Add Time: 0.2 (one or all) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 914143E > Sep > 91 > Wheel Center Caps - Rattling Noise Wheel Cover: All Technical Service Bulletins Wheel Center Caps - Rattling Noise Number: 91-414-3E Section: 3E Date: SEPT. 1991 Corporate Bulletin No.: 133503 ASE No.: A2, A3, A4, A5, B1 Subject: RATTLE NOISE AS A RESULT OF LOOSE WHEEL CENTER CAPS Model and Year: 1991 CAVALIER WITH Z24 TRIM PACKAGE Condition: Some 1991 "J" cars with the Z24 trim package may exhibit a rattling noise due to the wheel center hub cap being loose. Cause: Loose fit between the wheel and wheel center cap caused by oversize diameter in wheel. Correction: Using channel-lock pliers, with a cloth on cap face to protect the disc from damage, rework the center cap wire retaining ring (as shown in the picture) in five places to provide a tight fit of the cap to the improperly machined wheels. Bend the wire ring toward the cap disc as shown to obtain a permanent set of approximately one (1) wire diameter. This condition effects all 1991 Chevrolet J cars with Z24 from 1991 start of production through VIN breakpoint M7194096. Labor Operation Number: T1761 Labor Time: 0.2 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 914143E > Sep > 91 > Wheel Center Caps - Rattling Noise > Page 5080 Add Time: 0.2 (one or all) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut Torque 183 - 192 ft.lb Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Lug Nut Torque Patterns IMPORTANT Check all parts, including rims, lug studs, lug nuts, and mating surfaces of hubs and tire rims for rust, damage, or dirt. Clean mating surfaces with a wire brush to remove any foriegn material. Replace any damaged parts as needed. Careless installation of tire/rim assemblies in a vehicle is a major cause of tire installation problems. Proper installation, including fastener torque, is essential to economical, safe and trouble free service. Use only the proper sizes and types of fasteners for safe and proper service. Tighten the fasteners a quarter turn at a time using the tightening sequence diagram as a guide. This is very important to prevent misalignment of the wheel. Continue tightening the fasteners in sequence until the fasteners are tightened to the proper torque (See WHEEL FASTENER TORQUE). CAUTION: Improper torque or tightening sequence can cause distortion, fatigue cracks, or alignment problems. After driving the vehicle for a short distance, recheck the wheel fastener torque. Parts will usually seat naturally, reducing the torque on the fasteners. Retorque all fasteners to the proper torque. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Description and Operation Air Conditioning Switch: Description and Operation A/C "ON" Signal This signal indicates that the A/C control switch is turned "ON" and the pressure switch is closed. The computer uses this signal to adjust the idle speed, and on some models engages the A/C compressor clutch. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Cable: > 914131A > Sep > 91 > Heater - Low Output Air Door Cable: Customer Interest Heater - Low Output Number: 91-413-1A Section: 1A Date: SEPT. 1991 Corporate Bulletin No.: 131104 ASE No.: A7 Subject: LOW HEAT DELIVERY RELATED DIAGNOSIS REVISED PROCEDURE Model and Year: 1989-91 CAVALIER On customer comments of low heater output on 1989-91 J cars, before replacing a suspected defective engine cooling thermostat, proper diagnosis of the condition must be performed to avoid the possibility of a repeat repair. Follow "Diagnosis" as shown in Section 1A/1B of the appropriate Service Manual. After completing the diagnosis, use the following as a guide to the next corrective step: ^ If the diagnosis indicates a defective thermostat, refer to Section 6C for replacement. ^ If the diagnosis indicates a defective temperature control cable, refer to Section 1A/1B for replacement. ^ If the diagnosis indicates the temperature control cable is no longer "snapped" into its retainer, refer to "Temperature Control Cable Repair" in the 1991 Service Manual, Sections 1A/1B. ^ If the diagnosis indicates that the temperature control cable is out of adjustment, refer to the following procedure to repair. TEMPERATURE CONTROL CABLE ADJUSTMENT PROCEDURE Condition: 1. "Spring back" off full "hot" temperature control position (or not attaining full "cold" temperature door position). Condition: 2. "Spring back" off full "cold" temperature control position (or not attaining full "hot" temperature door position). Cause: The temperature control cable "clip" needs adjustment. Refer to the illustration for correct gripping of the "clip" during adjustment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Cable: > 914131A > Sep > 91 > Heater - Low Output > Page 5101 Correction For Number: 1. Grip "clip" at module end of cable while pulling temperature control lever to "hot" position. Correction For Number: 2. Grip "clip" at module end of cable while pushing temperature control lever to "cold" position. NOTICE: FAILURE TO GRIP "CLIP" CORRECTLY WILL DAMAGE ITS ABILITY TO HOLD POSITION ON THE CABLE. THE TEMPERATURE CONTROL CABLE MUST BE REPLACED IF "CLIP" RETENTION FAILS. Verify correct adjustment after repair by observing for no, or very liftle, "spring back" of the temperature control lever and listening for temperature door "slam" when the control lever is moved to full hot and cold positions quickly. Please note your copies of the Service Manuals in Sections 1A and 1B, under "Temperature Control Cable", with these new adjustment instructions. Warranty and Labor Information: Use the appropriate failure code for each occurrence. For thermostat or temperature control cable replacement, use current applicable warranty and labor information. For temperature cable repair at the heater control, use current heater warranty and labor information. For temperature control repair at the HVAC module or cable adjustment: Labor Operation Number: D0400 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Cable: > 914131A > Sep > 91 > Heater - Low Output Air Door Cable: All Technical Service Bulletins Heater - Low Output Number: 91-413-1A Section: 1A Date: SEPT. 1991 Corporate Bulletin No.: 131104 ASE No.: A7 Subject: LOW HEAT DELIVERY RELATED DIAGNOSIS REVISED PROCEDURE Model and Year: 1989-91 CAVALIER On customer comments of low heater output on 1989-91 J cars, before replacing a suspected defective engine cooling thermostat, proper diagnosis of the condition must be performed to avoid the possibility of a repeat repair. Follow "Diagnosis" as shown in Section 1A/1B of the appropriate Service Manual. After completing the diagnosis, use the following as a guide to the next corrective step: ^ If the diagnosis indicates a defective thermostat, refer to Section 6C for replacement. ^ If the diagnosis indicates a defective temperature control cable, refer to Section 1A/1B for replacement. ^ If the diagnosis indicates the temperature control cable is no longer "snapped" into its retainer, refer to "Temperature Control Cable Repair" in the 1991 Service Manual, Sections 1A/1B. ^ If the diagnosis indicates that the temperature control cable is out of adjustment, refer to the following procedure to repair. TEMPERATURE CONTROL CABLE ADJUSTMENT PROCEDURE Condition: 1. "Spring back" off full "hot" temperature control position (or not attaining full "cold" temperature door position). Condition: 2. "Spring back" off full "cold" temperature control position (or not attaining full "hot" temperature door position). Cause: The temperature control cable "clip" needs adjustment. Refer to the illustration for correct gripping of the "clip" during adjustment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Cable: > 914131A > Sep > 91 > Heater - Low Output > Page 5107 Correction For Number: 1. Grip "clip" at module end of cable while pulling temperature control lever to "hot" position. Correction For Number: 2. Grip "clip" at module end of cable while pushing temperature control lever to "cold" position. NOTICE: FAILURE TO GRIP "CLIP" CORRECTLY WILL DAMAGE ITS ABILITY TO HOLD POSITION ON THE CABLE. THE TEMPERATURE CONTROL CABLE MUST BE REPLACED IF "CLIP" RETENTION FAILS. Verify correct adjustment after repair by observing for no, or very liftle, "spring back" of the temperature control lever and listening for temperature door "slam" when the control lever is moved to full hot and cold positions quickly. Please note your copies of the Service Manuals in Sections 1A and 1B, under "Temperature Control Cable", with these new adjustment instructions. Warranty and Labor Information: Use the appropriate failure code for each occurrence. For thermostat or temperature control cable replacement, use current applicable warranty and labor information. For temperature cable repair at the heater control, use current heater warranty and labor information. For temperature control repair at the HVAC module or cable adjustment: Labor Operation Number: D0400 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > A/C Blower - Revised Service Procedure Blower Motor: Technical Service Bulletins A/C Blower - Revised Service Procedure Number: 91-252-1A Section: 1A Date: MARCH 1991 Corporate Bulletin No.: 071102R Subject: HEATER/AIR CONDITIONING - REVISED SERVICE PROCEDURE Model and Year: 1991 CAVALIER, CORSICA, BERETTA SERVICE UPDATE THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-131-1A, DATED DECEMBER 1990. THE 1990 L CAR HAS BEEN ADDED. ALL COPIES OF 91-131-1A SHOULD BE DISCARDED. Please mark a reference to this bulletin in the following 1991 service manuals: - J Car, Pages 1A-11,1B-43 - L Car, Pages 1A-14,1B-29 BLOWER MOTOR AND FAN ASSEMBLY 3.1L Engine (J and L) Remove or Disconnect: 1. Negative battery cable 2. Tower to tower brace - (J-car) 3. Electrical connections at blower motor 4. Blower motor cooling tube 5. Alternator bolt 6. Lift alternator and set aside 7. Blower motor retaining screws and blower motor assembly 8. Blower motor fan ^ Refer to "BLOWER MOTOR FAN REPLACEMENT" Install: 1. Blower motor assembly 2. Retaining screws 3. Alternator 4. Alternator bolt 5. Blower motor cooling tube 6. Electrical connections 7. Tower to tower brace 8. Negative battery cable 2.2L Engine (J and L car) 2.3L Engine (L car, Beretta GTZ only) Remove or Disconnect: 1. Negative battery cable 2. Cowl sight shield - (L car, Beretta GTZ only with 2.3L) 3. Electrical connections at blower motor 4. Blower motor cooling tube 5. Blower motor retaining screws Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > A/C Blower - Revised Service Procedure > Page 5112 6. Blower motor fan ^ Refer to "BLOWER MOTOR FAN REPLACEMENT" Install: 1. Blower motor assembly 2. Retaining screws 3. Blower motor cooling tube 4. Electrical connections 5. Cowl sight shield - (L car, Beretta GTZ only with 2.3L) 6. Negative battery cable BLOWER MOTOR FAN REPLACEMENT I. Remove Fan - Use heat knife or soldering iron. ^ Cut material on shaft axially in three places: Starting 1/2" from base of fan shaft, start cut into fan dome and continue to cut through the plastic material to the end of shaft so that the fan splits from the shaft. ^ Grasp fan and pull off the shaft. NOTICE: DO NOT HAMMER MOTOR OR PLACE HEAVY "SIDE WAY" IMPACT ON FAN OR MOTOR DAMAGE MAY OCCUR. IA. Alternate Methods To Remove Fan - Use small wheel or gear puller. Remove tip of fan, if necessary, at end of motor shaft using soldering iron or end cutting pliers, vise grip pliers or Channelock(R) pliers. Draw fan from motor shaft using a small puller. Hook legs of puller between fan lower rim and motor mounting plate. Thread center post of puller against the end of the motor shaft exposed in the above step. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > A/C Blower - Revised Service Procedure > Page 5113 - Use drill press or small arbor press. ^ Remove tip of fan, if necessary, at end of motor shaft using soldering iron or end cutting pliers, vise grip pliers or Channelock(R) pliers. ^ Support fan as shown, with blocks, angle iron, etc., while allowing the motor to be suspended as shown. ^ Place steady pressure on tip of motor shaft as shown, with a drill press or small arbor press and pin arrangement. Motor should fall freely from the fan after moving motor shaft about 1/2 inch. NOTICE: DO NOT HAMMER MOTOR OR PLACE HEAVY "SIDE WAY" IMPACT ON FAN OR MOTOR DAMAGE MAY OCCUR. II. Fan Installation - Insert fan on motor shaft. ^ Grasp fan by dome and by applying hand pressure to fan dome insert fan on motor shaft until fan is lightly seated on motor shaft. ^ Place fan and motor on a 13 mm (1/2") x 1/2" drive socket as shown in Figure 2. ^ While steadying the fan and motor, apply steady force to the rear of the motor shaft, using a drill press or small arbor press and pin arrangement, until the clearance between the motor mounting plate and the fan hub is 5.5 mm +/- 0.5 mm. ^ A 1/4" - 20 nut is approximately 5.5 mm. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > A/C Blower - Revised Service Procedure > Page 5114 Remove the spacers (nuts) by grasping fan dome and turn fan which will dislodge spacers from under fan. NOTICE: DO NOT HAMMER ON MOTOR TO INSTALL FAN OR DAMAGE TO MOTOR MAY OCCUR. To prevent motor shaft/bearing damage, do not apply force to motor housing to seat fan on motor. To prevent fan damage during installation, do not apply pressure to fan rim. It is necessary to ensure the proper replacement fan is used. Seal end housing of blower motor using "water resistant" tape (provided in motor kit). WARRANTY INFORMATION Labor Operation Number: D1322 with A/C D1320 without A/C Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 5115 Blower Motor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect blower motor electrical connections. 3. On 1989 models, remove plastic water shield from right side of cowl. 4. On 1990-92 3.1L/V6-192 engines, remove tower to tower brace assembly. 5. On all models, remove blower motor retaining screws and blower motor. 6. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations LH Front Of Dash, On Relay Bracket Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Front Of Dash. Center Front Of Dash, Below Wiper Motor Assembly Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > A/C Compressor Seal Washer - Reference Chart Compressor Shaft Seal: Technical Service Bulletins A/C Compressor Seal Washer - Reference Chart File In Section: 1 - HVAC Bulletin No.: 63-12-15 Date: November, 1996 INFORMATION Subject: Reference Chart for A/C Compressor Seal Washers Models: 1997 and Prior Passenger Cars (Except Corvette and GEO) 1997 and Prior Light Duty Trucks (Except Tracker) GMSPO A/C compressors include a seal washer kit. These kits contain various color edge painted washer seals and inserts in which only two (2) washers and possibly one (1) insert are used. It has come to our attention that some packaging discrepancies were found and some of the seals cannot be properly identified for installation. These seals are very close in size and some of the seals were inadvertently edge painted the wrong color or not painted. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > A/C Compressor Seal Washer - Reference Chart > Page 5127 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > A/C Compressor Seal Washer - Reference Chart > Page 5128 The chart shown will help to properly identify the seals. Use the chart by placing the seal over the pictured seal to identity inside and outside diameters and thickness. Because these seals are very similar in size, specifications are also listed in the chart. Important: If seals are damaged upon installation, obtain new seal kit. Seals will be available separately at a later date. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information > Technical Service Bulletins > Isolation Diodes - Replacement Information Compressor Clutch Diode HVAC: Technical Service Bulletins Isolation Diodes - Replacement Information Number: 93-163-8A Section: 8A Date: MAY 1993 Corporate Bulletin No.: 178201R ASE No.: A6 Subject: ISOLATION DIODES REPLACEMENT INFORMATION Model and Year: 1993 AND PRIOR YEAR PASSENGER CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 92-47-8A, DATED NOV. 1991. THE 1993 MODEL YEAR HAS BEEN ADDED AS WELL AS PART NUMBERS HAVE BEEN REVISED. THIS WILL ALSO UPDATE CERTAIN SERVICE MANUALS. ALL COPIES OF 92-47-8A SHOULD BE DISCARDED. Many of the electrical systems on our vehicles use a diode to isolate certain circuits and protect them from voltage spikes. Some of the circuits which may use such a diode are listed below: A/C Compressor Clutch ABS/4WAL NOTE: The ABS diode on the Delco Moraine system is hidden inside of an electrical connector under the carpet at the right kick panel. Wiper Charging System (hidden in wire harness) Parking Brake (vehicles with ABS) Relays Solenoids Diesel Glow Plug Circuit Day Time Running Lights Obtaining replacement diodes can sometimes be a problem. A universal diode, that meets the specifications in the chart below, may be used for the applications listed above. Since certain diode applications have specific part numbers, always reference the applicable GM parts catalogue before installing one of the universal diodes listed in this bulletin. When installing the new diode, use the following procedures to obtain a lasting repair: 1. If the diode is taped to the harness, remove all of the tape. 2. Paying attention to current flow direction, remove inoperative diode from the harness with a suitable soldering tool. If the diode is located next to a connector terminal, remove the terminal(s) from the connector to prevent damage from the soldering tool. 3. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 4. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. Reference Figure 1 for replacement diode symbols and current flow explanations. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information > Technical Service Bulletins > Isolation Diodes - Replacement Information > Page 5133 Attach the new diode to the wire(s) using 60/40 rosin core solder. Use a heat sink (aluminum alligator clip) attached across the diode wire ends to protect the diode from excess heat. Follow the manufacturers instructions for the solderin equipment you are using. 5. Install terminal(s) into the connector body if previously removed in step number 2. 6. Tape the diode to the harness or connector using electrical tape. To prevent shorts to ground and water intrusion completely cover all exposed wire and diode attachment points. NOTE: A universal diode with a 3 amp, 400 PIV (Peak Inverse Voltage) rating can be used in all of the previously mentioned applications. The following 1993 Service Manuals will need to be updated with the correct part numbers and rating changes. Carline Page All J, L, W, and UO 8A-5-12 Heat sink, part number 276-1567, can be obtained from Radio Shack. We believe the diodes and heat sink listed in this article as well as their manufacturer to be reliable. There may be additional manufacturers or equivalent 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. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information > Technical Service Bulletins > Page 5134 Compressor Clutch Diode HVAC: Locations RH Front Of 2.2L In A/C Compressor Clutch Connector Applicable to: 2L/4-134 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations RH Side Of Engine Compartment. RH Rear Of Engine Compartment, Behind Strut Tower Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5138 Compressor Clutch Relay: Description and Operation Wiring Diagram For A/C Clutch Control The ECM controls the A/C compressor clutch relay. When the A/C is turned on, the ECM delays the clutch engagement to allow the IAC valve to raise the engine idle speed to compensate for the added load. The ECM allows the relay to disengage the A/C clutch at wide open throttle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair Evaporator Core: Service and Repair Fig. 12 Heater Core & Blower Motor 1. Disconnect battery ground cable. 2. Discharge air conditioning system, then drain cooling system. 3. Raise and support vehicle. 4. Remove rear lateral transaxle strut and mount, if equipped. 5. Disconnect heater core heater hoses. 6. Disconnect evaporator lines at evaporator core. 7. Disconnect heater and evaporator assembly drain tube. 8. Lower vehicle and remove right and left hush panels, steering column trim cover and glove compartment. 9. Remove heater duct retaining screw and heater duct. 10. Remove heater core cover attaching screws, then gently pull cover rearward and out of vehicle, Fig. 12. When removing heater core assembly, pull assembly straight toward interior of vehicle until plastic drain tube clears cowl. If assembly is tilted in any direction before tube clears cowl, the drain tube may break. 11. Remove heater core retaining clamps and heater core from case. 12. Remove defroster vacuum actuator to module case attaching screw. 13. Remove evaporator cover and core. 14. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations Evaporator Tube & Accumulator Tube Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Heater Control Valve: > 914131A > Sep > 91 > Heater - Low Output Heater Control Valve: Customer Interest Heater - Low Output Number: 91-413-1A Section: 1A Date: SEPT. 1991 Corporate Bulletin No.: 131104 ASE No.: A7 Subject: LOW HEAT DELIVERY RELATED DIAGNOSIS REVISED PROCEDURE Model and Year: 1989-91 CAVALIER On customer comments of low heater output on 1989-91 J cars, before replacing a suspected defective engine cooling thermostat, proper diagnosis of the condition must be performed to avoid the possibility of a repeat repair. Follow "Diagnosis" as shown in Section 1A/1B of the appropriate Service Manual. After completing the diagnosis, use the following as a guide to the next corrective step: ^ If the diagnosis indicates a defective thermostat, refer to Section 6C for replacement. ^ If the diagnosis indicates a defective temperature control cable, refer to Section 1A/1B for replacement. ^ If the diagnosis indicates the temperature control cable is no longer "snapped" into its retainer, refer to "Temperature Control Cable Repair" in the 1991 Service Manual, Sections 1A/1B. ^ If the diagnosis indicates that the temperature control cable is out of adjustment, refer to the following procedure to repair. TEMPERATURE CONTROL CABLE ADJUSTMENT PROCEDURE Condition: 1. "Spring back" off full "hot" temperature control position (or not attaining full "cold" temperature door position). Condition: 2. "Spring back" off full "cold" temperature control position (or not attaining full "hot" temperature door position). Cause: The temperature control cable "clip" needs adjustment. Refer to the illustration for correct gripping of the "clip" during adjustment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Heater Control Valve: > 914131A > Sep > 91 > Heater - Low Output > Page 5153 Correction For Number: 1. Grip "clip" at module end of cable while pulling temperature control lever to "hot" position. Correction For Number: 2. Grip "clip" at module end of cable while pushing temperature control lever to "cold" position. NOTICE: FAILURE TO GRIP "CLIP" CORRECTLY WILL DAMAGE ITS ABILITY TO HOLD POSITION ON THE CABLE. THE TEMPERATURE CONTROL CABLE MUST BE REPLACED IF "CLIP" RETENTION FAILS. Verify correct adjustment after repair by observing for no, or very liftle, "spring back" of the temperature control lever and listening for temperature door "slam" when the control lever is moved to full hot and cold positions quickly. Please note your copies of the Service Manuals in Sections 1A and 1B, under "Temperature Control Cable", with these new adjustment instructions. Warranty and Labor Information: Use the appropriate failure code for each occurrence. For thermostat or temperature control cable replacement, use current applicable warranty and labor information. For temperature cable repair at the heater control, use current heater warranty and labor information. For temperature control repair at the HVAC module or cable adjustment: Labor Operation Number: D0400 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Control Valve: > 914131A > Sep > 91 > Heater - Low Output Heater Control Valve: All Technical Service Bulletins Heater - Low Output Number: 91-413-1A Section: 1A Date: SEPT. 1991 Corporate Bulletin No.: 131104 ASE No.: A7 Subject: LOW HEAT DELIVERY RELATED DIAGNOSIS REVISED PROCEDURE Model and Year: 1989-91 CAVALIER On customer comments of low heater output on 1989-91 J cars, before replacing a suspected defective engine cooling thermostat, proper diagnosis of the condition must be performed to avoid the possibility of a repeat repair. Follow "Diagnosis" as shown in Section 1A/1B of the appropriate Service Manual. After completing the diagnosis, use the following as a guide to the next corrective step: ^ If the diagnosis indicates a defective thermostat, refer to Section 6C for replacement. ^ If the diagnosis indicates a defective temperature control cable, refer to Section 1A/1B for replacement. ^ If the diagnosis indicates the temperature control cable is no longer "snapped" into its retainer, refer to "Temperature Control Cable Repair" in the 1991 Service Manual, Sections 1A/1B. ^ If the diagnosis indicates that the temperature control cable is out of adjustment, refer to the following procedure to repair. TEMPERATURE CONTROL CABLE ADJUSTMENT PROCEDURE Condition: 1. "Spring back" off full "hot" temperature control position (or not attaining full "cold" temperature door position). Condition: 2. "Spring back" off full "cold" temperature control position (or not attaining full "hot" temperature door position). Cause: The temperature control cable "clip" needs adjustment. Refer to the illustration for correct gripping of the "clip" during adjustment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Control Valve: > 914131A > Sep > 91 > Heater - Low Output > Page 5159 Correction For Number: 1. Grip "clip" at module end of cable while pulling temperature control lever to "hot" position. Correction For Number: 2. Grip "clip" at module end of cable while pushing temperature control lever to "cold" position. NOTICE: FAILURE TO GRIP "CLIP" CORRECTLY WILL DAMAGE ITS ABILITY TO HOLD POSITION ON THE CABLE. THE TEMPERATURE CONTROL CABLE MUST BE REPLACED IF "CLIP" RETENTION FAILS. Verify correct adjustment after repair by observing for no, or very liftle, "spring back" of the temperature control lever and listening for temperature door "slam" when the control lever is moved to full hot and cold positions quickly. Please note your copies of the Service Manuals in Sections 1A and 1B, under "Temperature Control Cable", with these new adjustment instructions. Warranty and Labor Information: Use the appropriate failure code for each occurrence. For thermostat or temperature control cable replacement, use current applicable warranty and labor information. For temperature cable repair at the heater control, use current heater warranty and labor information. For temperature control repair at the HVAC module or cable adjustment: Labor Operation Number: D0400 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 5164 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 5165 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 5166 Heater Core: Service and Repair Heater Module Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 5167 Heater Module Legend 1. Disconnect battery ground cable and drain cooling system. 2. Raise and support vehicle. 3. Remove rear lateral transaxle strut and mount, if equipped. 4. Disconnect heater case drain tube, then disconnect heater core heater hoses. 5. Lower vehicle and remove right and left hush panels, steering column trim cover and glove compartment. 6. Remove heater duct retaining screw and heater duct. 7. Remove heater core cover attaching screws, then gently pull cover rearward and out of vehicle, Fig. 12. When removing heater core assembly, pull assembly straight toward interior of vehicle until plastic drain tube clears cowl. If assembly is tilted in any direction before tube clears cowl, the drain tube may break. 8. Remove heater core retaining clamps and heater core from case. 9. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 331222A > Dec > 93 > A/C - Slow Defrost of Windshield Housing Assembly HVAC: Customer Interest A/C - Slow Defrost of Windshield Group Ref.: HVAC Bulletin No.: 331222A Date: December, 1993 SUBJECT: SLOW DEFROST OF WINDSHIELD (INSTALL NEW DEFROSTER NOZZLE AND/OR NOZZLE SEAL) MODELS: 1991-93 CHEVROLET CAVALIER 1992-93 PONTIAC SUNBIRD THIS BULLETIN IS BEING REVISED TO CORRECT A PART NUMBER IN THE CORRECTION PROCEDURE. CONDITION: Some owners of the above vehicles may express concern about the time it takes the defroster to clear the windshield. This condition is most prevalent under very cold conditions. CAUSE: The seal between the I/P and the HVAC module may not be thick enough. This could allow defroster air to escape below the I/P pad and not reach the windshield. CHEVROLET ONLY Also, the vanes in the defroster nozzle assembly may not be directing the optimum supply of air to the windshield. CORRECTION: Pontiac Only: Replace the current 12 mm windshield defrost nozzle and air distribution seal with the new 23 mm seal, P/N 22594128. Affected Vehicles: 1992 - S.O.P. to E.O.P. 1993 - S.O.P. to Lordstown Ramos P7584932 PS835281 Chevrolet Only: 1. Replace defroster nozzle assembly with P/N 22593234. Affected Vehicles: 1991-1993 - S.O.P. to E.O.P. 2. Replace the current 12 mm windshield defrost nozzle and air distribution seal with the new 23 mm seal, P/N 22594128. Affected Vehicles: 1992 - S.O.P. to E. 0. P. 1993 - S.O.P. to Lordstown Ramos P7315356 PS835231 SERVICE INFORMATION: Follow service procedures outlined in Section 8C of the appropriate service manual. NOTE: The I/P carrier does not need to be completely removed from the vehicle to gain access to the defroster nozzle or the defroster nozzle seal. PARTS INFORMATION: Pontiac Only: Seal, w/s defrost nozzle and air distribution: P/N 22594128 Chevrolet Only: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 331222A > Dec > 93 > A/C - Slow Defrost of Windshield > Page 5176 Grille, w/s defrost nozzle - left: P/N 22593234 Seal, w/s defrost nozzle and air distribution: P/N 22594128 Parts are currently available from GMSPO. WARRANTY INFORMATION: Labor Operation Number: T3374 Labor Time: 2.2 HRS. - Pontiac Only Labor Time: 2.6 HRS. - Chevrolet Only Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 331222A > Dec > 93 > A/C - Slow Defrost of Windshield Housing Assembly HVAC: All Technical Service Bulletins A/C - Slow Defrost of Windshield Group Ref.: HVAC Bulletin No.: 331222A Date: December, 1993 SUBJECT: SLOW DEFROST OF WINDSHIELD (INSTALL NEW DEFROSTER NOZZLE AND/OR NOZZLE SEAL) MODELS: 1991-93 CHEVROLET CAVALIER 1992-93 PONTIAC SUNBIRD THIS BULLETIN IS BEING REVISED TO CORRECT A PART NUMBER IN THE CORRECTION PROCEDURE. CONDITION: Some owners of the above vehicles may express concern about the time it takes the defroster to clear the windshield. This condition is most prevalent under very cold conditions. CAUSE: The seal between the I/P and the HVAC module may not be thick enough. This could allow defroster air to escape below the I/P pad and not reach the windshield. CHEVROLET ONLY Also, the vanes in the defroster nozzle assembly may not be directing the optimum supply of air to the windshield. CORRECTION: Pontiac Only: Replace the current 12 mm windshield defrost nozzle and air distribution seal with the new 23 mm seal, P/N 22594128. Affected Vehicles: 1992 - S.O.P. to E.O.P. 1993 - S.O.P. to Lordstown Ramos P7584932 PS835281 Chevrolet Only: 1. Replace defroster nozzle assembly with P/N 22593234. Affected Vehicles: 1991-1993 - S.O.P. to E.O.P. 2. Replace the current 12 mm windshield defrost nozzle and air distribution seal with the new 23 mm seal, P/N 22594128. Affected Vehicles: 1992 - S.O.P. to E. 0. P. 1993 - S.O.P. to Lordstown Ramos P7315356 PS835231 SERVICE INFORMATION: Follow service procedures outlined in Section 8C of the appropriate service manual. NOTE: The I/P carrier does not need to be completely removed from the vehicle to gain access to the defroster nozzle or the defroster nozzle seal. PARTS INFORMATION: Pontiac Only: Seal, w/s defrost nozzle and air distribution: P/N 22594128 Chevrolet Only: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 331222A > Dec > 93 > A/C - Slow Defrost of Windshield > Page 5182 Grille, w/s defrost nozzle - left: P/N 22593234 Seal, w/s defrost nozzle and air distribution: P/N 22594128 Parts are currently available from GMSPO. WARRANTY INFORMATION: Labor Operation Number: T3374 Labor Time: 2.2 HRS. - Pontiac Only Labor Time: 2.6 HRS. - Chevrolet Only Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Housing Assembly HVAC: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High Oil Pressure Gauge: All Technical Service Bulletins Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Housing Assembly HVAC: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High > Page 5188 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Housing Assembly HVAC: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High > Page 5194 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Retrofitting R-12 Vehicles to R-134A Refrigerant: Technical Service Bulletins A/C - Retrofitting R-12 Vehicles to R-134A Group Ref.: HVAC Bulletin No.: 331226 Date: January, 1994 INFORMATION SUBJECT: RETROFITTING R-12 VEHICLES TO R-134a MODELS: 1994 AND PRIOR YEARS, PASSENGER CARS AND TRUCKS WITH R-12 A/C SYSTEMS There has been a great deal of information presented by the media regarding the need to retrofit vehicles produced with R-12, to a substitute refrigerant. This bulletin will outline GM's position and future plans on this subject. Most important, there is currently NO requirement to retrofit any R-12 vehicle. Vehicles built with R-12 can be serviced with R-12, as long as the refrigerant is available. At some point in time, R-12 may become either too scarce or too expensive to economically justify service on some vehicles with R-12. By that time, GM will provide you with instructions on retrofitting those vehicles from R-12 to R-134a. GM vehicle divisions, platforms, and component suppliers have been actively working on the details of retrofitting R-12 vehicles. An enormous amount of work is required to determine how hundreds of vehicle models can be satisfactorily retrofitted. Additional information will be provided as it becomes available. The following items contain important technical information that should answer many of the questions, and correct some misconceptions reported in the media. SUBSTITUTE REFRIGERANTS R-134a is the only approved substitute refrigerant that GM recommends and it should only be used if a complete retrofit procedure has been performed. None of the other refrigerants currently being marketed as replacement or drop-in substitutes for R-12 are approved for use in GM vehicles. R-12 and R-134a are not interchangeable. R-134a cannot be added to fill a low R-12 system. The combination of the two materials can cause high system pressures, which could cause damage to the system. Retrofitting an R-12 vehicle to R-134a requires careful preparation to insure that neither the vehicle nor the A/C service equipment has become contaminated. RESIDUAL MINERAL OIL The concern that mineral oil is chemically incompatible with R-134a and/or PAG lubricant has been proven to be untrue. A normal charge of mineral oil left in the A/C system after a retrofit to R-134a will not damage the system. Mineral oil, however, does not mix well with R-134a, and will not provide adequate lubrication. Tests on both the orifice tube and TXV systems show that the mineral oil parks in places such as the accumulator, and does not appreciably affect performance or damage the system. The retrofit service bulletin will specify the correct oil to be used. It is important that this oil recommendation be followed carefully. RESIDUAL R-12 Residual R-12 left in a system, due to improper retrofit service procedures, may result in system damage unless the residual R-12 is kept below the 2 percent limit specified by the Society of Automotive Engineers' Specification J-1661. New service methods are being developed to minimize the level of R-12 remaining in the A/C system after the retrofit procedure is completed. Following these new procedures will be critical to insure that the above limits are met. SYSTEM FLUSHING R-11, a material commonly used as an A/C system flushing solvent, has been found to be chemically incompatible with PAG lubricant. Technicians should be aware that residual R-11 remaining in an R-12 system will be very damaging if the vehicle is retrofitted to R-134a later in its life. For many years GM has recommended the use of in-line filters as an alternative to system flushing. SYSTEM FLUSHING, USING EITHER R-11 OR ANY OTHER FLUSHING MATERIAL, IS NOT APPROVED BY GM FOR ANY A/C SYSTEM. DESICCANT PROTECTION Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Retrofitting R-12 Vehicles to R-134A > Page 5199 It has been reported that the desiccant (moisture absorption material) used in 1992 and older R-12 A/C systems is incompatible with R-134a and PAG oil. The older desiccant was designed specifically for R-12 systems, but testing has shown that it is NOT necessary to replace the older desiccant just because the vehicle is being retrofitted to R-134a. 1993 and newer GM vehicles use desiccant designed to be compatible with both R-12 and R-134a systems. The amount of desiccant used in most GM vehicles is designed to last for at least seven years. To help maintain adequate protection for vehicles that must be retrofitted, it is recommended that the accumulator/dryer, which contains the desiccant, be replaced if the vehicle is more than five years old. "O" RINGS While continuing to service with R-12, be sure to use "O" rings and seal materials which are compatible with R-134a and PAG oil. This practice will eliminate concern in case the vehicle requires retrofitting later in its life. All "O" rings and seal materials available from GMSPO are compatible with R-134a systems. RETROFITTED SYSTEM PERFORMANCE Currently, it appears that for most GM vehicles, the retrofit procedure will require minimal changes to the existing system. Some vehicles may need additional parts and/or procedures to provide acceptable performance and/or durability. Our testing has shown that vehicles that have undergone recommended retrofit procedures will, in most climatic conditions, be minimally affected in terms of A/C performance. SERVICE POLICY Basic service policy is as follows: During Warranty - If an R-12 produced vehicle A/C system must be repaired or recharged under warranty, repairs will be completed using R-12. If R-12 is unavailable or unaffordable, GM will notify the dealer body and will pay for the warranty repair and the retrofit to R-134a. NOTE: It a customer requests that an in-warranty vehicle be converted to R-134a, and the R-12 system is functioning properly, the customer will be expected to pay for the retrofit. Out of Warranty - The cost of the conversion will be the responsibility of the customer. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a Technical Service Bulletin # 431207E Date: 970101 A/C - Retrofitting R-12 to R-134a File In Section: 1 - HVAC Bulletin No.: 43-12-07E Date: January, 1997 INFORMATION Subject: Guidelines for Retrofitting R-12 Vehicles to R-134a Models: 1984-94 Passenger Cars and Trucks (See List Below) This bulletin is being revised with the following changes: 1. Addition of all remaining GM vehicles, as listed. 2. Format rearranged for easier use. Please discard Corporate Bulletin Number 43-12-07D (Section 1 - HVAC). Car/Truck Platform Coverage Starts: 1984 - A, B, D, E, F, J, K, P, Y Carlines 1985 - C, M, N, R, S Carlines 1986 - H Carline 1987 - L, V (Allante) Car lines; M/L, G, R/V, S/T, P Truck lines 1988 - T (LeMans), E (Reatta), W Car lines; C/k, MED. Duty Truck lines 1989 - Tracker 1990 - U Van Vehicles Not Covered: T (Chevette and T1000), G RWD, C RWD, and X Car If a vehicle is not covered in the list above, GM's recommendation is that the vehicle continue to be serviced with R-12. This bulletin outlines the detailed retrofit procedures, as well as providing background information on many components and procedures. It is important to follow the bulletin, since each car and truck line has unique parts and procedures. However, the basic procedure is simple, and will become easier as you complete more retrofits. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5205 Retrofit Requirements The customer should be reminded that there is NO requirement in the U.S. to retrofit any vehicle produced with R-12. Vehicles built with R-12 can be serviced with R-12 as long as it is available (except in certain Canadian Provinces). GM has taken steps to extend the supply of R-12 and recommends that all R-12 vehicles continue to be serviced with R-12 as long as it is available. Training Video Before doing a retrofit the first time, it is recommended that you view the Certified Plus Training Video, Program number 51010.15, "R-134a Retrofit for GM Cars and Trucks". Table of Contents A. Retrofit Procedure 1. Inspect Condition of Vehicle 2. Recover the R-12 (new method) 3. Install the service port conversion fittings 4. Install any additional parts needed 5. Evacuate and recharge with new PAG or V5 retrofit oil and R-134a 6. Install the retrofit label Platform Details Compressor Replacement Chart B. General Information 1. Performance 2. Leakage 3. Desiccant 4. Improved Cooling Performance 5. PAG or V5 Oil Compatibility 6. Refrigerant Oil Level Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5206 C. Parts Information D. Warranty Information 1. Vehicle Still in Warranty 2. Customer Paid' Retrofitting Costs 3. Labor Time Information Notes on Retrofit Important: Before proceeding with any retrofit, make sure you have all component Parts required on hand to perform a proper and complete repair with Minimal downtime. R-12 Removal Prior to Retrofit To prepare a system for retrofitting, the R-12 must be recovered and the system must be completely evacuated. Evacuation is necessary to insure that small amounts of R-12 and air remaining in the system are removed. This will prevent cross contamination of the two refrigerants, which could lead to reduced A/C system reliability and performance. It is very important that the specified times for waiting after recovery and evacuation not be reduced. This time is required to sufficiently remove residual R-12 from the oil in the system. A considerable amount of testing has determined that the following procedure is required to achieve satisfactory results and conform to SAE J 1661: 1. Inspect Condition of Vehicle Install the gauge set on the high and low side ports. Use normal diagnostic procedures to find the cause of the vehicle's reported condition. One of three conditions will exist with the refrigerant system: a. System pressure correct, no leaks - proceed to Step 2 (Recovery). This would normally apply when: 1. The system must be recovered/recharged for a repair to a system other than the A/C system, or 2. Where the A/C system condition did not involve leaks, but requires recovery/recharge to replace a component. b. Compressor not operating, but some charge. Leak test to find the leak, complete Step 2 (Recovery), then correct the leak before proceeding with Step 3 (Conversion port installation). c. No charge in system - proceed with the Conversion port installation in Step 3. Use the ACR4 to evacuate for 5 minutes. If the leak can be heard, repair the leak. If the leak cannot be heard, charge with 1/2 pound of R-134a. Leak test with the J 39400 Leak Detector, recover the R-134a, repair any additional leaks found, and proceed with the evacuation in Step 5. 2. Recover the R-12 from the System Notice: THIS PROCEDURE IS DIFFERENT THAN THE NORMAL (NON-RETROFIT) RECOVERY PROCEDURE. R-12 will be recovered through the HIGH SIDE SERVICE PORT ONLY, WITH THE ENGINE RUNNING. Recovery through the low side will not effectively remove the R-12 from the accumulator, resulting in possible damage to the retrofitted system. Important: Vehicle must be above 50° F (10° C) to allow for complete recovery of the R-12. If it is not, either allow it to warm up in the shop overnight, or increase the evacuation time in Step 5.a to 30 minutes. a. Connect the recovery hose from the R-12 recovery cart (ACR3) to the middle port of the A/C gauge set. Open the oil drain valve on the ACR3 cart long enough to drain the oil. Failure to do so could cause excessive amounts of oil to build up in the separator, resulting in damage to the recovery cart compressor. b. Start the engine. Leave the hood up, and the windows open. On vehicles with manual A/C controls, set the A/C controls to normal A/C mode, high blower, and temperature control to full cold. On cars with automatic A/C controls, set the temperature to 75° F, "AUTO" mode, and manually select high blower. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5207 Make sure the vehicle compressor is engaged. Turn the cart on and start the recovery cycle. OPEN ONLY THE HIGH SIDE VALVE ON THE GAUGE SET. The vehicle system should eventually shut the compressor off. If the low side pressure drops below 15 psi, and the compressor does not turn off, turn it off now (go to "VENT" or "ECON" mode), but leave the engine running and the blower on "high". c. After the recovery cart shuts off the first time, wait 5 minutes. If the pressure on either the high or the low side rises above 0 psi, restart the recovery process. After the second shutoff, wait 2 minutes. If the pressure again rises above 0 psi, restart, and after shutoff, again wait 2 minutes. The process can be stopped when the pressure does not rise above 0 psi after 2 minutes. The engine can be shut off at this time. d. Remove the R-12 reclaim hose and the gauge set from the vehicle. Any repairs needed should be done at this time. If any components other than the compressor are replaced, they should be installed dry, and no extra oil should be added. 3. Install the Service Port Conversion Fittings Important: For GEO vehicles, skip to Step 4. Fitting installation is covered in that step. For vehicles that require a HPCOS, see Step 4. Some of these vehicles use a specific combination fitting to mount the HPCOS, which includes the high side service port fitting and the HPCOS port. The low side fitting is installed as detailed below. See "Platform Details" for further information. Important: A new tool kit, P/N J 39500-250, has been released. This kit contains the following items: ^ J 39500-71 Oil Injection Bottle Conversion Kit (includes 3 12 oz bottles, an extender tube, caps, and fittings) ^ J 39500-275 Tool kit, including the following: (See Figure 2) - J 34611-A Double ended valve core remover - J 25498-A High side adapter fitting - J 38702 Deep valve core adapter fitting Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5208 - J 41265 Thread cleaning wire brush - J 41266 Low side port thread restorer - J 41267 High side port thread restorer - J 39037 High side octagon socket - J 41256 Low side octagon socket New low profile, quick connect couplers, J 39500-20A (High side), and J 39500-24A (Low side), have been released as essential tools, to attach to the ACR4 (see Figure 3). These are much smaller couplers than the existing ones, and will allow attachment to the port fittings in much tighter quarters. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5209 Select and install the proper R-134a fittings (shown in Figure 4) from the chart below, based on how the ACR4 couplers will attach. Also, remember to check for proper hood clearance with the conversion fittings. Try the straight fittings first. The two-piece high side fitting is used when the existing fitting is screwed into the pipe fitting (some 1992, and nearly all 1993 models, use these fittings). Use the 90° elbow if the straight fitting does not allow the ACR4 couplers to connect. Fitting Type High Side Low Side Straight 52467941 52467943 Straight Two-piece 52467324 N/A 90° Elbow 52469054 52469055 The fittings should be installed as follows: a. Remove the caps from the R-12 fittings. Remove any dirt or grease from the port threads using the thread cleaning wire brush, J 41265. Inspect the fittings for thread damage. If any damage is found, use the port thread restorer (J 41266 low side, J 41267 high side) to repair the thread. For the two-piece fitting, remove the existing R-12 fitting and discard it. Use tool J 38704A (previously released, not part of the above kit) to remove the fitting. Make sure to hold the line securely to prevent damage when removing the existing fitting. If the fitting cannot be removed easily, use the saddle clamp valve listed below and seal the R-12 port and cap permanently. b. Install the selected fitting onto the existing R-12 fitting. Leave the valve core in the straight fittings, and remove the valve core when using the 90° fittings. If the valve cores need to be removed at a later time, they can be removed with the straight conversion fittings in place. On the low side straight fitting, use the J 34611-A tool to remove the core pin in the conversion fitting, then remove the core valve from the original R-12 fitting. Always recover the charge before valve core removal. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5210 Use the octagon sockets on the straight fittings (J 39037 high side, and J 41256 low side). Torque the new fitting until it seats. The fitting should seat fully BEFORE reaching 11 N.m (8 lb ft). If 11 N.m (8 lb ft) of torque is reached and the fitting has not seated, it is probable that the threads have been damaged. In this case, remove the fitting and use the thread restorer listed above. Reinstall the fitting, adding one drop of a thread locking compound such as Loctite(R) 242. The fittings (except the two-piece) have a thread locking compound applied to the threads. This compound will set up enough to restrict removal of the fitting in about 15 minutes. The fittings can now be used to evacuate the system (see Step 5). An additional type of conversion port fitting has been developed. This fitting is called a saddle clamp valve (see Figure 5). It can be clamped directly on a metal refrigerant line, and will be used if the existing fitting is damaged or is inaccessible. A drop of a thread locking compound, such as Loctite(R) 242, should be used on each bolt to prevent the threads from loosening. The R134a saddle clamp valve part numbers are: If an existing R-12 service port is not used, it must be rendered inoperative. Place several drops of a thread locking compound, such as Loctite(R) 243, in the valve core, and onto the cap threads. Secure the cap and let it set for 15 minutes. 4. Install Any Additional Parts Needed See "Platform Details" after Step 6. If a vehicle is listed as a "Basic Retrofit", no additional parts are required (except for compressors, see the Compressor Replacement Chart at the beginning of Platform Details). If no parts are required, PROCEED TO STEP 5. Compressors Compressors do not need to be replaced as part of a normal retrofit, unless indicated in the Compressor Replacement Chart. An R-12 compressor that is operating properly can, in most cases, be left in the vehicle when it is retrofitted to R134a. However, if a compressor failure is the reason the vehicle is in for service, and the vehicle will be retrofitted, OR if a vehicle has already been retrofitted with R-134a and the compressor fails at some time in the future, new compressors for use with R-134a are available. See the GMSPO Parts Catalog for specific part numbers. DO NOT use a replacement R-12 compressor for any vehicle retrofitted to R-134a (unless it is the new "oil-less" design). See "Compressor Availability" at the end of the Compressor Replacement Chart. Accumulator /Dryer If the vehicle is more than 5 years old, the Accumulator/Dryer (A/D) should be replaced to ensure that moisture is removed from the system. See the instructions for proper A/D identification in General Information. High Pressure Cut-Off Switch (HPCOS) Most trucks, and some 1984-93 B and D cars, require that a HPCOS be added to protect the refrigerant system during long idles at high temperature. The HPCOS kit (P/N 15981985) contains the switch, wire harness, heat sealing splice connectors, switch "0" ring, and installation instructions. A saddle clamp adapter (P/N 15985307), or a special dual fitting, is mounted to the high pressure line, and provides the port to mount the switch. A drop of a Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5211 thread locking compound, such as Loctite(R) 242, should be used on each bolt of the saddle clamp to prevent the threads from loosening. Some vehicles produced during the second half of the 1993 model year will already have a factory installed HPCOS. Check the back of the compressor for this switch. If present, the above switch will not have to be added. 5. Evacuate the System, and Recharge with PAG or V5 Retrofit Oil and R-134a Newly designed low profile quick connect couplers for the ACR4, J 39500-20A and J 39500-24A, have been released. These should be installed before proceeding with the evacuation. See Step 3, and Figure 3. a. Connect the R-134a cart (ACR4) to the system. Open the coupler valves on the hoses so that the pressures can be read on the gauges. On the cart, open the HIGH SIDE VALVE ONLY. DO NOT OPEN THE LOW SIDE VALVE! Program the cart for a 15 minute evacuation. Important: If the vehicle has been at outside temperatures of less than 50° F (10° C), or at high altitudes (above 3000 ft), use a 30 minute evacuation to insure complete removal of the R-12. If the vacuum pump will not start and a "H-P" reading is indicated on the ACR4 display, loosen the fitting at the high side line connection to the ACR4 to relieve pressure in the line. Tighten the fitting after pressure has been relieved. DO NOT USE THE RECOVERY MODE TO RELIEVE LINE PRESSURE. b. Start the evacuation. For a proper evacuation, the cart must pull down to 28-29 in. Hg. at sea level (reduce by 1 in. for each 1000 ft above sea level). Check the low side gauge for proper vacuum level, to make sure the new fittings are operating properly. While the evacuation is being done, the Retrofit label can be filled out and installed (see Step 6). Important: If the compressor was replaced at the same time as this retrofit, and the new compressor was shipped with the correct amount of PAG oil already in it, DO NOT add any additional oil to the system! Go to Step D. If an "oil-less" compressor was installed, add oil in Step C. A new retrofit oil for use with V5 compressor vehicles has been released. This oil will be used ONLY for retrofitted vehicles in which the original V5 compressor is retained. IT WILL NOT BE USED IF A COMPRESSOR IS REPLACED AT THE TIME OF THE RETROFIT. Failure to use this oil may significantly shorten the useful life of the compressor. Important: If the V5 Retrofit oil is not available from GMSPO, the compressor MUST BE REPLACED! To summarize the correct retrofit oil usage: ^ Compressor replaced during retrofit - NO OIL ADDED if new compressor shipped with oil - 8 oz. of PAG oil (9 oz of PAG oil with V5 compressor) added if compressor shipped without oil ("oil-less" design) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5212 ^ PAG oil used for future service if needed (mark PAG on box on label, Figure 6). ^ HR6 or R4 original compressor RETAINED - add 8 oz FAG oil to system ^ V5 original compressor RETAINED - add 9 oz V5 Retrofit oil to system. If V5 Retrofit oil is not available from GMSPO, REPLACE THE COMPRESSOR. c. Based on the above chart, add oil if needed. Use the new oil bottle and the extended tube kit, J 39500-71. Fill the bottle with at least 10 oz of oil. Attach the new bottle to the back of the ACR4, and open the oil fill valve. Allow the correct amount of oil to be drawn into the system. DO NOT allow the oil level to drop below the end of the pickup tube. This will prevent any air from being drawn into the system. If any oil was removed during the R-12 recovery evacuation steps, DO NOT add additional oil to replace it. d. Determine the correct amount of R-134a to use. Check the existing label of the vehicle for the R-12 charge amount. Use the formula {(R12 x .9) - .25 lb = R-134a} to determine the correct charge. This can also be stated as: Take 90% of the R12 charge, and subtract 1/4 lb. Follow the directions for the ACR4 cart to recharge the system. At the end of the process, "CPL" will be displayed. Close the high side valve. e. Start the vehicle, turn on the A/C system, and confirm that pressures are within normal operating ranges, as shown in the 1994 Service Manual. The 1994 Service Manuals can be used as a reference for diagnosis and specification of retrofitted systems. On some vehicles with automatic A/C controls or low charge diagnostics, the A/C compressor may not engage if any diagnostic codes were set during the retrofit. Check to see if any codes were set in either the HVAC or Engine Control systems. If they were, clear the codes following the directions in the Service Manual. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5213 f. TO INSURE AN ACCURATE CHARGE AMOUNT, IT IS IMPORTANT TO CLEAR THE ACR4 OF ANY REMAINING REFRIGERANT. Close the high side coupler valve and remove the high side hose from the vehicle. Then, open both the high and low side valves on the ACR4. After the pressures on both gages are at low side pressure, close the low side coupler valve. See Step G below, then remove the low side hose from the vehicle. Shut off the engine. Install the service port caps on the new fittings. These serve as a seal and can prevent system leaks. g. In the unlikely event that the low side fitting leaks when the coupler is removed, use the following procedure: 1. Immediately reinstall the coupler on the fitting. 2. Find the valve core remover J 34611-A. 3. Remove the coupler. 4. Use the double-ended valve core remover to turn the valve core pin counter-clockwise until the leak stops. 5. Install the cap. If the leak was substantial or continued for an extended period of time, it is highly recommended to evacuate and recharge the system to insure proper performance. If there is any question, the system can be rechecked by repeating Step F. h. Leak test any new port fittings, adapters, or valves that were installed, and any joints that were opened or repaired during the retrofit process, using tool J 39400. 6. Install the Retrofit Label The retrofit label (P/N 21030857, roll of 250) has been developed following SAF specifications to insure a smooth transition from R-12 to R-134a, and to insure a professional approach to the retrofit and a quality repair. Following the instructions in this bulletin will insure that the retrofit meets the SAE standards. Fill in the new label using a typewriter or a ball-point pen (see Figure 6). Select a location for the label that will be easily visible. Some suggested areas are the radiator support panel, an area near the existing R-12 charge label, or a flat surface near the high or low side service ports. The area selected should be a clean, underhood, painted sheet metal surface, and should be degreased and wiped down with a non-petroleum based cleaner. Do not install the label on a rubber surface. Apply the label, then apply the clear overlay to the label. Do not remove, cover, or render unreadable the existing R-12 charge label. DO cover the R-12 refrigerant charge amount on the existing label with an indelible, preferably black, marker. Platform Details Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5214 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5215 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5216 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5217 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5218 FOR ALL VEHICLES EXCEPT GEO, see the "Compressor Replacement Chart" at the end of this section. Compressor replacement requirements ARE NOT LISTED in the platform details (except for application details), except as noted below for Y car and P and Medium Duty truck. Compressor Replacement Chart Important: It is important to check the date code on the compressor. Any vehicle may have had a compressor replaced either during or after the warranty period. The date code will determine whether or not the compressor must be replaced. Compressor Availability A new compressor for use with R-134a systems will be shipped with the correct amount of PAG oil installed (see "IMPORTANT" below). Do not add any additional oil in Step 5 of the retrofit procedure if a compressor is to be replaced with a new R-134a compressor at the same time the initial retrofit is Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5219 being done. Important: During 1996, "oil-less" compressors began to be serviced with NO added oil. New part numbers will be issued, and both the box and the compressor will be clearly marked to indicate that no oil is present. If you receive one of these newer compressors, simply add the normal amount of oil to the system in Step 5 of the retrofit procedure (8 oz of PAG oil, or 9 oz of PAG oil with V5 compressor). These "oil-less" compressors are compatible with EITHER R12 or R-134a. Geo Models Compressors DO NOT HAVE TO BE REPLACED as part of the retrofit. New compressors are shipped with enough oil to accommodate the entire A/C system. Do not add additional PAG oil to the system it the compressor is being replaced. 1985-88 Nova, 1989-93 Prizm (S) 1. Using the Service Manual, remove the following components in the order given: a. Receiver/dryer. b. Loosen evaporator to compressor (suction) pipe (to be reinstalled) c. 1985-92 only: Loosen compressor to condenser (compressor discharge) pipe (to be reinstalled). d. 1985-88 only: Service Valve & Extension Housing on compressor (to be installed). e. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High and low side adapter fittings (see Step 3 of the retrofit procedure for detailed installation instructions). c. 1985-88 only: Service Valve & Extension Housing on compressor using new 0-rings. Six small 0-rings and one large 0-ring are required. d. Evaporator to compressor (suction) pipe 0-ring. e. 1985-92 Compressor to condenser (discharge) hose 0-ring. f. Receiver/dryer and 0-rings. R-134a amount: 85-92 - 650 grams (1.43 lb) 93 - 700 grams (1.54 lb) PAG oil amount: 100 cc (3.0 oz) Parts Required: Receiver/dryer: 85-88 - 94855761 89-93 - 94855762 Adapter Fittings: Low Side - 94855760 High Side - 94855759 0-Rings: 85-88 Compressor - Small 0-rings (6 required) - 94857336 - Large 0-ring - 94857337 85-93 Receiver/Dryer (2) - 94845949 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5220 85-93 Suction hose - 94855765 85-92 Discharge hose - 94845943 1985-88 Sprint, 1989-93 Metro (M) 1. Using the Service Manual, remove the following components in the order given: a. Receiver/dryer. b. Evaporator to compressor (suction) pipe. c. Compressor to condenser (compressor discharge) pipe. d. Joint service connector on compressor (to be reinstalled). e. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High and low side adapter fittings (see Step 3 of the retrofit procedure for detailed installation instructions). c. Joint service connector to compressor. Use new 0-rings. Six small 0-rings and one large 0-ring are required. d. Evaporator to compressor (suction) pipe, and new 0-ring. e. Compressor to condenser (discharge) hose and new 0-ring. f. Receiver/dryer and 0-ring. R-134a amount: 500 grams (1.10 lb) PAG oil amount: 100 cc (3.0 oz) Parts Required: Receiver/dryer: 85-86 - 91172081 87-88 - 91172079 89-93 - 96068480 Adapter Fittings: Low Side - 91172092 85-88 - High Side - 91172094 89-93 - High Side - 52467941 0-Rings: Compressor - Small 0-rings (6 required) - 91172095 - Large 0-ring - 96068915 Receiver/Dryer (2) - 96068488 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5221 89-93 - Suction hose - 96068490 89-93 - Discharge hose - 96068489 Suction hose: 85-86 - 91172086 85-86 Dealer installed: 91172087 87-88 - 91172088 89-93 - w/turbo - 96069121 - w/o turbo - 91172089 Discharge hose: 85-86 - 91172082 85-86 Dealer installed: 91172083 87-88 - 91172084 89-93 - 96069024 1989-93 Tracker 1. Using the Service Manual, remove the following components in the order given: a. Receiver/dryer. b. Evaporator to compressor (suction) pipe. c. Compressor to condenser (compressor discharge) pipe. d. Joint service connector on compressor (to be reinstalled). e. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High and low side adapter fittings (see Step 3 of the Retrofit procedure for detailed installation instructions). c. Joint service connector to compressor. Use new 0-rings. Six small 0-rings and one large 0-ring are required. d. Evaporator to compressor (suction) pipe, and new 0-ring. e. Compressor to condenser (discharge) hose and new 0-ring. f. Receiver/dryer and 0-ring. R-134a amount: 550 grams (1.21 lb) PAG oil amount: 100 cc (3.0 oz) Parts Required: Receiver/dryer - 91172080 Adapter, Low Side - 91172092 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5222 Adapter, High Side - 91172093 0-Rings: Compressor - Small (6) - 91172095 Large - 96068915 Receiver/dryer (2) - 96068488 Suction hose - 96068490 Discharge hose - 96068489 Suction hose - 91172091 Discharge hose - 91172085 1985-89 Spectrum and 1990-93 Storm (R) 1. Using the Service Manual, remove the following components in the order given: a. Condenser (Storm) or radiator grille (Spectrum) (to be reinstalled). b. Triple switch (Storm) or dual pressure switch (Spectrum) (to be reinstalled). c. Receiver/dryer. d. Evaporator to compressor (suction) pipe. e. Check valve from high side service valve (discard). f. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High side adapter fitting (see Step 3 of the retrofit procedure for detailed installation instructions). Low Side - Part of suction hose c. Evaporator to compressor (suction) pipe, and new 0-rings. d. Receiver/dryer and 0-rings. e. Triple switch or dual switch, and new 0-ring. f. Condenser or radiator grille. R-134a amount: 91 - 500 grams (1.10 lb) 92-93 - 600 grams (1.32 lb) PAG oil amount: 150 cc (4.50 oz) Parts Required: Receiver/dryer: 85-89 - 97104795 90-91 - 97104797 92-93 - 97104798 Adapter, High Side: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5223 85-89 - 97104794 90-93 - 97104793 Adapter, Low Side: Part of Hose Asm. 0-rings: Receiver/dryer 85-91 - 94154048 92-93 - 94461700 Switch/pipe - 94461902 Suction hose: 85-86: 1.5L - 97104799; 1.6L - 97104800 90-93: 1.6L - 97104801; 1.8L - 97104803 B. General Information Several items affecting the performance and durability of the system should be considered: 1. Performance When performed properly, the retrofit from R-12 to R-134a will have minimal effect on the system's performance in most climatic conditions found in the United States and Canada. 2. Leakage Experience has shown that most leakage in an A/C system is due to leaks at the joints, or through a small leak in a hose, usually at the coupling. The R-134a molecules are smaller than R-12, and a small leak may result in a faster loss of refrigerant with R-134a. Because of this, it is very important to leak check all vehicles using the J 39400 leak detector, BEFORE the retrofit is performed, and repair any leaks found. "0" rings and hoses used in most GM vehicles are compatible with R-134a and do not need replacement during a retrofit. "0" rings or hoses installed in previous repairs may have been of non-compatible materials if GM parts were not used and will be more likely to deteriorate and leak than the original equipment materials. All "0" rings and hoses available through GMSP0 are compatible with R-134a. Remember that the normal policy is to replace the "0" rings whenever a joint is opened for any reason. 3. Desiccant You may have heard that the currently used desiccant in the accumulator is not compatible with R-134a. Extensive testing has shown that it is, in fact, suitable for use with R-134a, once it has been in service in an R-12 system. The accumulator in these models will not have to be changed during the retrofit procedure, unless the vehicle is more than 5 years old. Vehicles more than 5 years old should have the A/D replaced to add new desiccant for proper system drying. In the event that an accumulator/dryer (A/D) needs to be replaced on a retrofitted system in the future, only A/D's with XH-7 desiccant should be used. The service parts for the 1993 vehicles contain only XH-7 desiccant. The parts for the 1992 and older vehicles may contain either XH-5 or XH-7. Parts containing XH-7 can be identified (see Figure 1) by 1) an "A" printed on the top of the A/D; or 2) if there is a label on top of the A/D, there will be a square with an "A" inside; or 3) if there is a time code and date printed on top of the A/D just under the "Harrison" logo, the A/D contains XH-7. A/D's containing XH-5 can still be used on R-12 vehicles. 4. Improved Cooling Performance There have been service bulletins issued in the past with information improving the cooling performance of existing R-12 systems. These bulletins can also be used to improve the performance of retrofitted vehicles in high ambient temperature climates. 5. PAG or V5 Oil Compatibility Contrary to information published to date outside of General Motors, mineral oil and PAG or V5 oil ARE chemically compatible. The mineral oil left in the system after reclaiming the R-12 can remain in the system with no harmful effects. However, the mineral oil will not mix with the R-134a, and so will not circulate and perform its lubricating function. Testing has shown that most of the mineral oil will eventually collect in the Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5224 accumulator. The system will operate properly as long as refrigerant charge amounts are strictly adhered to. 6. Refrigerant Charge Level The retrofit R-134a charge level is more critical than with R-12 systems. Overcharging may push the mineral oil out of the AID, and cause it to circulate as a liquid. This is more likely to result in compressor damage. Undercharging may lead to loss of performance. It is very important to clear the hoses during the charging operation, to insure that all the refrigerant is delivered to the vehicle A/C system. This is covered in Step 6D of the Retrofit Procedure. C. Parts Information Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5225 Important: All of the following parts are NOT NEEDED for a normal retrofit. Follow the bulletin procedures to determine which parts you need! Individual vehicle kits are not necessary, since most of the parts are generic and only a few parts are needed for most vehicles. GEO Parts are listed in "Platform Details." Parts are currently available from GMSPO. D. Warranty Information 1. Vehicle Still Within the Original New Vehicle Limited Warranty Period When GM models for the years listed in the bulletin require repairs to the refrigerant system and the vehicles are still covered under the New Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431207E > Jan > 97 > A/C - Retrofitting R-12 to R-134a > Page 5226 Vehicle Limited Warranty, dealers are instructed to proceed as follows: Important: On vehicles equipped with A/C systems NOT produced by GM (i.e., rear A/C systems in van conversions), consult the manufacturer of that A/C system for retrofit guidelines. ^ Offer the customer the option of repairing and recharging the system with R12, or retrofitting after repair and recharging with R-134a at no additional charge. ^ Provide the owner with, and review the information contained in, the "Converting Your Auto Air Conditioning System to Use the New Refrigerant" brochure. (Brochure, Form GM-0011, can be ordered free of charge from GM Fulfillment HQ, Phone 1-800-269-5100). ^ Record the customer's choice on the repair order and, as with all properly completed repair orders, ask the customer to sign on the appropriate line acknowledging the repairs requested. ^ Under no circumstances should the retrofit to R-134a be performed unless the customer has had the option explained prior to repair. Once the vehicle has been retrofitted to R-134a, a significant expenditure would be incurred to go back to R-12, in the event the customer has changed his/her mind. THIS OFFER APPLIES ONLY TO VEHICLES REQUIRING A/C REFRIGERANT SYSTEM REPAIRS UNDER THE TERMS OF THE NEW VEHICLE LIMITED WARRANTY. It is not a special policy, and any existing deductibles still apply. This is simply an option being offered to the customer during the warranty period at this time. GM reserves the right to terminate this offer at any time. If the R-12 refrigerant system does not require discharging for a warranty repair, but the customer requests a retrofit to R-134a, the retrofit WOULD BE PERFORMED AT THE CUSTOMER'S EXPENSE, EVEN DURING THE WARRANTY PERIOD. 2. Customer Paid Retrofitting Costs If the customer requests a retrofit to R-134a, for a specific vehicle whose retrofit parts and procedures have been released in this bulletin, the customer would be expected to pay the costs to retrofit under the following conditions: ^ The vehicle is no longer covered by the terms of the New Vehicle Limited Warranty. ^ The vehicle is covered by warranty, but the repair covered under the warranty does not require evacuating and recharging the refrigerant system. 3. Labor Time Information For Vehicles Repaired Under Warranty: Use existing labor operations for correcting the original condition. The quantity of R-134a used should be charged to the normal labor operation (not D4500), just as if it were R-12. Use D4500, 0.3 HR., to charge for parts and labor, for all of the following items: ^ Additional time for recovery of R-12 to meet SAE standards; ^ Install high and low side service port converter fittings; ^ Add PAG or V5 retrofit oil; ^ Complete label information and install. Add 0.2 hours to D4500 for installation of the HPCOS. Use T5321, 0.3 HR., for the Pontiac Bonneville hood seal installation. ANY PARTS OR LABOR TIME OTHER THAN THOSE LISTED ABOVE SHOULD BE CHARGED TO THE REGULAR LABOR OPERATION CORRESPONDING TO THE ORIGINAL CONDITION THAT 1S BEING REPAIRED. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 631209 > May > 96 > A/C - R12 or R134a Service Recommendations Technical Service Bulletin # 631209 Date: 960501 A/C - R12 or R134a Service Recommendations File In Section: 1 - HVAC Bulletin No.: 63-12-09 Date: May, 1996 INFORMATION Subject: Service Issues for Vehicles with R12 or R134a Air Conditioning Systems Models: 1988-96 Passenger Cars and Trucks R12 Service Recommendations As you know, production of R12 refrigerant ceased on December 31, 1995. Although R12 will no longer be manufactured, there is a reserve supply of R12 available. This reserve, along with strict A/C repair service adherence to proper refrigerant recycling procedures, should assure continued availability to meet consumers' needs. R12 can and should continue to be used to service vehicles built with R12 A/C systems as long as it is available. If R12 is no longer available or affordable, a system retrofit utilizing R134a is recommended. R134a IS THE ONLY SUBSTITUTE REFRIGERANT RECOMMENDED BY GM FOR USE IN GM VEHICLE A/C SYSTEMS, AND THEN ONLY AFTER FOLLOWING THE PROPER RETROFIT PROCEDURES FOR THE SPECIFIC MODEL. All new vehicle manufacturers have chosen R134a for retrofit. One of the key reasons is to protect both the service industry and consumers from the high costs that would result from purchasing equipment necessary to service multiple refrigerants. This position also reduces the threat of recycled refrigerant contamination. GM currently offers a simple, low cost R12 to R134a retrofit on many of its late model, front wheel drive passenger cars. Dealers should discuss this capability with owners of these specific models, listed in Retrofit Corporate Bulletin # 43-12-07D, whenever a repair to the A/C refrigerant system is required. Early retrofit of these specific models will aid in prolonging availability of the R12 supply and provide dealer service technicians the opportunity to become more familiar with the proper procedures for performing a retrofit. Remember - R12 and R134a refrigerant are not interchangeable! They cannot be mixed together. In fact, despite the claims of some refrigerant manufacturers, no proposed R12 refrigerant substitute can be added to, mixed with or used to "top off" an R12 system. Under provisions of law covering the service of refrigerants, mixing dissimilar refrigerant products during service is prohibited. To Summarize GM R12 Service Policy 1. Service R12 vehicles with good quality new or recycled R12 as long as it is available. 2. Purchase R12 from a reliable supplier. GMSPO has a supply of high quality R12 available. Dealers are requested to use only R12 supplied by GMSPO for warranty repairs. This high quality refrigerant will insure system performance and avoid the possibility of introducing contaminated material into the customer's A/C system. 3. Carefully test recovered R12 using the PureGuard monitor. On recovery equipment not protected by the PureGuard, always test the recovery cylinder prior to recharging a vehicle A/C system. 4. Discuss the R12 to R134a retrofit option with owners of GM vehicles listed in Retrofit Corporate Bulletin # 43-12-07D. Provide owner with a copy of the pamphlet "Converting Your Auto Air Conditioning System to Use the New Refrigerant". 5. Become familiar with retrofit procedures and exercise care in the handling of dissimilar refrigerants to prevent contamination. R134A Service Recommendations When servicing a previously retrofitted vehicle, there is concern that if all of the R12 is not completely removed prior to the retrofit procedure, it could contaminate your R134a equipment and recovery tank when a subsequent A/C repair is performed. Although the number of retrofits being performed today is minimal, the volume will increase as R12 prices rise. GM Service Technology Group is in the process of field testing a new R134a refrigerant purity tester similar to the PureGuard R12 refrigerant tester you now use. This new tool will mount to your ACR4 R134a Recovery Recycle and Recharge cart and sample all R134a refrigerant prior to recovery. It is expected that testing of this tool will be completed this year. This new tool, the Pureguard 2, will also test vehicles and your recycle tank for air contamination, which is threatening A/C system performance. High levels of air have been found in the recovery tanks on a number of R12 and R134a recovery carts. Air contamination is caused by improper recovery Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 631209 > May > 96 > A/C - R12 or R134a Service Recommendations > Page 5231 procedures and short-cutting refrigerant recycling times. Use the following procedure for testing and correcting air contamination in your A/C service equipment. 1. Make certain that the ACR4 equipment has not been used for at least 12 hours. It is recommended that the equipment be left in an area where the temperature will remain constant overnight to allow the temperature of the refrigerant in the tank to stabilize. 2. Record the surrounding air temperature next to the ACR4 refrigerant tank. Important: A major assumption is that the ambient air temperature next to the tank represents the refrigerant temperature in the tank. Failure to take care in measuring the temperature could result in unnecessary work. 3. Close both liquid (blue) and vapor (red) valves on the ACR4 tank. 4. Disconnect low side (blue) service hose from the back of the ACR4. 5. Slowly disconnect the tank vapor hose (red) from the back of the ACR4 and connect it to the low side service port. 6. Open the vapor (red) valve on the tank and record the tank pressure on the low side gage. 7. Restore hoses to the original position. 8. Referring to the Table, find the ambient temperature measured in Step 2. Compare the pressure reading from Step 6 to the "maximum allowable pressure". If the pressure reading from Step 6 is less than the "maximum allowable pressure", no further action is necessary. Important: The closer the tank pressure is to the desired tank pressure, the better the A/C system will perform. 9. If the pressure reading from Step 6 exceeds the maximum allowable pressure from the Table, open both tank valves and operate the ACR4 through 4 or 5 evacuation cycles. This will activate the automatic air purge to lower the tank pressure. Important: Station should not be connected to vehicle. 10. Repeat the tank pressure checking procedure the next day to determine if the pressure has been reduced to acceptable levels. If the tank pressure has been reduced but is not acceptable, cycle with ACR4 through more evacuation cycles and recheck the next day. Continue process until acceptable pressure is obtained. If the tank pressure is not reduced through the evacuation cycling, then Kent-Moore should be contacted at 1-800-345-2233. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 531205 > May > 95 > Contaminated R12 Refrigerant - Testing & Handling Refrigerant: Technical Service Bulletins Contaminated R12 Refrigerant - Testing & Handling FILE IN SECTION: 1 - HVAC BULLETIN NO.: 53-12-05 DATE: May, 1995 SUBJECT: Contaminated R12 Refrigerant Testing and Handling MODELS: 1994 and Prior Passenger Cars and Trucks with R12 A/C Systems The J 39851 "PureGuard" R12 refrigerant monitor was recently shipped to all GM dealers as an essential tool to test R12 refrigerant. Dealers are strongly urged to install this protective device on their ACR3 or other R12 recovery equipment immediately. The PureGuard is easily installed on any recovery cart (20 minutes), requires no recovery cart modifications, is fully automatic (no training required) and does not increase the time required to perform normal A/C service procedures. Proper use of this tool can: ^ Prevent damage to your R12 recovery/recycling equipment. ^ Prevent contamination of previously recovered R12 in the recovery tank. ^ Prevent loss of your recovered R12 as contaminated refrigerant will activate automatic air purge system. ^ Prevent the spread of contaminated R12 to other vehicles you service. If your dealership has multiple R12 recovery stations which are not protected, use the PureGuard to check the refrigerant in these recovery tanks for contamination at least once each week. Simply connect the PureGuard blue service hose (that would normally be connected to the vehicle low side service port) to the red or vapor side of any recovery cart tank and run the test. It is also important to check a tank containing recovered/recycled material for purity before installation on your charging equipment. Even new R12 refrigerant purchased from sources other than GM should be tested for contamination prior to use. Sources of Contaminated R12 Refrigerant Since refrigerant testing has not been a standard practice in the mobile A/C repair industry, the amount of R12 refrigerant contamination is unknown. As R12 prices rise and supplies are depleted, it is anticipated that contaminated R12 refrigerant may become more prevalent from the following as well as other sources: ^ The use of R12 refrigerant substitutes without installation of unique service fittings and proper identification labeling. ^ Improper use of R12 substitutes, such as topping off R12 systems with R134a or other refrigerants available to "do-it-yourselfers". ^ Poor quality or contaminated new or reprocessed R12 refrigerant. R12 can and should continue to be used to service vehicles built with R12 as long as it is available. Combining any refrigerant with R12 results in a refrigerant mixture which cannot be used in an A/C system. R134a is the only substitute refrigerant approved by GM and should only be used when the appropriate retrofit service bulletin procedures are explicitly followed. Use of any other substitute refrigerant requires the purchase of additional dedicated recovery, recycling (if applicable) and charging equipment to service each substitute refrigerant used. However, you should know that the Environmental Protection Agency (EPA) has listed several products as acceptable replacements for R12 mobile A/C systems under the Significant New Alternatives Policy (SNAP). Some of these products are: R134a, R401c (a DuPont refrigerant blend) and FRIGC (another refrigerant blend). It is important to understand that the SNAP program only considers the health, safety and environmental characteristics of a chemical. It does not test for A/C system cooling performance or durability. That judgment is deferred to the vehicle manufacturer. Use of any R12 refrigerant substitute without dedicated service equipment, unique fittings, labels and refrigerant testing prior to recovery, could result in contamination of the R12 supply and the loss of the R12 recycling program. What To Do When Contamination is Detected Repeat the test to verify contaminated refrigerant is present. Clear the PureGuard following the instructions listed on the face panel, then perform a second test to verify that the vehicle A/C system contains contaminated or mixed refrigerant. Contact the vehicle owner to advise that previous A/C system repairs were apparently performed with an R12 refrigerant substitute. Suggest the owner Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 531205 > May > 95 > Contaminated R12 Refrigerant - Testing & Handling > Page 5236 contact or return to the previous repair facility. Explain that environmental regulations prohibit repair facilities from discharging ozone depleting A/C refrigerants into the atmosphere. Explain that recovery of this unknown refrigerant could damage your service equipment. If the customer wishes to pursue repairs through your facility, it is recommended that the proper A/C service equipment be purchased. General Motors recommends the Kent-Moore J 41428 "Scavenger", an air operated refrigerant recovery station, be used to remove unknown refrigerants. The air operated feature reduces the hazard of recovering potentially flammable refrigerants. Dealers should evaluate the need to purchase the equipment based on the number of contaminated vehicles they encounter. As an alternative to the initial purchase of a recovery only station, dealers should check locally for A/C specialty shops which may have the equipment to service substitute or contaminated refrigerants. They may be able to provide contaminated refrigerant recovery service to the dealer. The GM Service Technology Group has tested a recovery procedure where a 15 or 30 pound DOT approved refillable tank is fully evacuated then connected to a vehicle A/C system to recover the charge. Testing has shown that even when the recovery tank is cooled down in dry ice, the procedure does not guarantee the entire charge will be recovered. Since EPA regulations require full recovery of ozone depleting substances, GM does not recommend this procedure. Contaminated Refrigerant Disposal Although A/C refrigerant testing and disposal have not been a service practice in the mobile A/C industry, It has been common in the stationary A/C service industry for many years. Listed at the end of this bulletin are companies that provide refrigerant disposal service for the stationary A/C industry. Please be advised that GM has not independently evaluated these companies and is not in any way endorsing or promoting the use of these companies. Each of these companies has expressed an interest in providing refrigerant disposal service to GM dealers. In working with the stationary A/C industry, these companies typically receive large volumes of different refrigerants that have been mixed together. Unfortunately, because the volume of material returned by the mobile A/C industry will be in much smaller quantities, the cost of handling will be greater. To arrange for return of the refrigerant, simply call the company nearest you using the phone number listed below. The company will advise you on billing and shipping procedures. Disposal cost will vary between $3.00 and $5.00 per pound plus freight and handling. Shipping charges will vary by distance and location. In general, a 7 to 10 day turn-around time on the tank can be expected. The tank can be shipped via common carrier. Documents that your refrigerant has been properly disposed of will be sent to you with the return of your tank. As an alternative, many dealerships already have contracts in place with a disposal company who manages their hazardous wastes. In these cases, the disposal service may agree to handle containers of mixed refrigerants. Initially, the local disposal companies may be surprised by this inquiry. They may want to evaluate how much material will be collected before deciding whether to provide this service. As we move forward with the practice of testing R12 refrigerant, it will take time for all the questions to be answered. STG will provide additional information as soon as it is available. Understanding The PureGuard The PureGuard is a highly sensitive instrument capable of detecting R12 with 3% or less cross-contamination with other refrigerants. Any refrigerant mixture in excess of this amount poses a threat to both your refrigerant supply and recovery equipment. The PureGuard uses a pass/fail approach when monitoring the refrigerant and is precisely calibrated to cut power to the recovery machine if it encounters R12 mixed with any substitute refrigerants. The PureGuard ignores the presence of the air, dyes or oils in the refrigerant sampled. At least 20 psi must be present in the vehicle's A/C system for the PureGuard to function. Otherwise, refrigerant cannot be introduced to the PureGuard's test chamber. If a vehicle's A/C system contains less than 20 psi, it is an indication that the vehicle's system is nearly depleted of refrigerant. Occasionally, erratic PureGuard operation or service code 002 display will be encountered when A/C system pressure is exactly 20 psi. If this occurs, simply cycle the on/off switch to reset the PureGuard. After the 30 second PureGuard warm-up cycle, proceed immediately with vehicle recovery operation. Feedback from the field has indicated PureGuard service code 002 will also be displayed if the oil drain port is not sealed. Make sure the "0" ring seal in the cap is in place and that the cap is tight. If the PureGuard fails to clear or if you experience any other problems operating the PureGuard, contact Kent-Moore Technical Service at 1-800-345-2233. The unit should not be returned without first contacting Kent-Moore to obtain return authorization. Refrigerant Disposal Locations: United States Refrigerant Reclamation Inc. 12420 North Green River Rd. Evansville, IN 47711 800-207-5931, FAX - 812-867-1463 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 531205 > May > 95 > Contaminated R12 Refrigerant - Testing & Handling > Page 5237 Omega Refrigerant Reclamation 5263 North Fourth St. Irwindale, CA 91706 310-698-0991, FAX 310-696-1908 Refrigerant Management Svcs of Georgia 216 F. Atlanta Hwy. Cumming, GA 30130 Ph/FAX 800-347-5872 Refrigerant Reclaim Inc. 122 Old Stage Coach Rd. Dumfries, VA 22026 800-238-5902, FAX 703-441-0393 Gartech Refrigerant Reclamation Ctr. 2002 Platinum Garland, TX 75042 214-272-4070, FAX 214-272-8548 National Refrigerants, Inc. 11401 Roosevelt Blvd. Philadelphia, PA 19154 215-698-6620, FAX 215-602-8205 CFC Reclamation 1321 Swift North Kansas City, MO 64116 816-471-2511 Full Cycle-Global 550 James Street Lakewood, NJ 08701 908-370-3400, FAX - 908-370-3088 Refrigerant Reclaim Svcs, Inc. dba Full Cycle-Global 121 S. Norwood Drive Ft. Worth, TX 76053-7807 817-282-0022, FAX - 800-831-6182 Full Cycle-Global 2055 Silber, Ste. 109 Houston, TX 77055 713-681-7370, FAX - 713-681-9947 Full Cycle-Global 343 South Airline Hwy. Gonzales, LA 70737 504-644-5303, FAX - 504-644-1809 Full Cycle-Global 2966 Wireton Blue Island, IL 60406 708-388-8551, FAX - 708-388-8550 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431223 > Sep > 94 > A/C Refrigerant - Contamination Refrigerant: Technical Service Bulletins A/C Refrigerant - Contamination File In Section: 1 - HVAC Bulletin No.: 43-12-23 Date: September, 1994 Subject: Contaminated A/C Refrigerant Models: 1994 and Prior Passenger Cars and Trucks with R12 Air Conditioning Systems Government regulations limit the production of R12 refrigerant, commonly referred to as Freon, during 1994/1995 and restrict manufacture of new R12 material effective January 1, 1996. As R12 prices rise and supplies are depleted, it is anticipated non-approved substitute refrigerants and/or poor quality R12 material sold as new or reprocessed may become more prevalent. The Mobile Air Conditioning Society (MACS) recently expressed concern over reports of the sale of R12 refrigerant containing as high as 15% contamination by R22, a refrigerant commonly used in stationary home systems but unsuitable for use in mobile units. GM dealers should be careful to protect against contaminating their existing supplies of R12 or the A/C systems in customers' vehicles they service by dealing with reputable suppliers. All R12 refrigerant purchased for warranty repairs should be purchased through GM SPO to ensure GM quality standards are met. The use of non-approved R12 refrigerant substitutes, some of which contain flammable materials, has also been reported by MACS. These products are available to "do-it-yourselfers" who, in many cases, believe they are harmless replacements for the small cans of R12 used so commonly in the past. Once added to the A/C system, the vehicle can no longer be serviced using R12 recovery/recycling equipment without: - Risking permanent damage to recovery/recycling equipment - Contaminating the previously recovered R12 material in the recovery tank - Spreading the contamination when the recovered material is used to charge other vehicles or - Possible loss of the recovered material if the contaminated level is high enough to activate the air purge system Contaminated refrigerant also impacts customer satisfaction through poor vehicle A/C performance and loss of A/C system compressor/component durability. System or component failure resulting from the use of refrigerant which does not meet GM specification is not covered by the "New Vehicle Warranty". Unfortunately, there is no simple method to identify if a "do-it-yourselfer" or repair shop has added to or recharged a system with a non-approved refrigerant. The inability to protect against the spread of contaminated refrigerant threatens the recycling program and the industry's desire to maximize use of the remaining R12 supply. Beginning in 1993, General Motors STG, Harrison Division, Research Labs and Kent-Moore worked in conjunction with suppliers of various technologies to develop a tester to identify contaminated refrigerant in vehicle A/C systems before recovery. During development of the technology, several dealer service manager focus group studies were conducted to identify design features to best suit dealership needs. The discussions and surveys clearly indicated the desire for a dedicated instrument, permanently mounted to the refrigerant recovery cart to ensure ALL vehicles are automatically tested prior to recovering refrigerant. Testing ALL refrigerant for contamination prior to recovery is the ONLY means to ensure customer satisfaction, protect recovery equipment and avoid unintentional venting of refrigerant by your dealership. General Motors has evaluated all available technology for this project and only the J 39851 R12 "Pureguard" meets General Motors' specifications. The J 39851 R12 Pureguard Refrigerant Monitor has been classified as an essential tool and will be shipped by Kent-Moore to your dealership beginning in September of 1994. The essential price of the R12 "Pureguard" is $561 (for Canadian dealers the price is $800 Canadian). If your dealership has multiple R12 recovery equipment, additional units may be ordered from Kent-Moore for $561 at 1-800-345-2233. Features of the R12 "Pureguard" include: - Universally mounts to R12 Recovery Equipment - Automatically interrupts power to the Recovery Equipment when contaminated refrigerant is identified - Fully automatic design does not require technician action, training or interpretation - LCD displays Pureguard functions Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 431223 > Sep > 94 > A/C Refrigerant - Contamination > Page 5242 - Meets GM contamination sensitivity requirements - Self calibrating - Micro-processor controlled - Audio alarm alerts technician Other Refrigerant Identifiers are being advertised which may be available this A/C season. However, ONLY the Kent-Moore J 39851 R12 "Pureguard" meets General Motors' current specifications which ensure recovered refrigerant is compatible with General Motors vehicles and General Motors approved recovery systems. An R134a Pureguard Refrigerant Identifier is currently under development and is anticipated to be available in early 1995. The contamination of R134a refrigerant is not expected to be a concern until the program to retrofit R12 vehicles to R134a becomes more widely used. Future bulletins will be issued to address the recovery and disposal of contaminated refrigerant. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 331226 > Jan > 94 > A/C - Retrofitting R-12 Vehicles to R-134A Refrigerant: Technical Service Bulletins A/C - Retrofitting R-12 Vehicles to R-134A Group Ref.: HVAC Bulletin No.: 331226 Date: January, 1994 INFORMATION SUBJECT: RETROFITTING R-12 VEHICLES TO R-134a MODELS: 1994 AND PRIOR YEARS, PASSENGER CARS AND TRUCKS WITH R-12 A/C SYSTEMS There has been a great deal of information presented by the media regarding the need to retrofit vehicles produced with R-12, to a substitute refrigerant. This bulletin will outline GM's position and future plans on this subject. Most important, there is currently NO requirement to retrofit any R-12 vehicle. Vehicles built with R-12 can be serviced with R-12, as long as the refrigerant is available. At some point in time, R-12 may become either too scarce or too expensive to economically justify service on some vehicles with R-12. By that time, GM will provide you with instructions on retrofitting those vehicles from R-12 to R-134a. GM vehicle divisions, platforms, and component suppliers have been actively working on the details of retrofitting R-12 vehicles. An enormous amount of work is required to determine how hundreds of vehicle models can be satisfactorily retrofitted. Additional information will be provided as it becomes available. The following items contain important technical information that should answer many of the questions, and correct some misconceptions reported in the media. SUBSTITUTE REFRIGERANTS R-134a is the only approved substitute refrigerant that GM recommends and it should only be used if a complete retrofit procedure has been performed. None of the other refrigerants currently being marketed as replacement or drop-in substitutes for R-12 are approved for use in GM vehicles. R-12 and R-134a are not interchangeable. R-134a cannot be added to fill a low R-12 system. The combination of the two materials can cause high system pressures, which could cause damage to the system. Retrofitting an R-12 vehicle to R-134a requires careful preparation to insure that neither the vehicle nor the A/C service equipment has become contaminated. RESIDUAL MINERAL OIL The concern that mineral oil is chemically incompatible with R-134a and/or PAG lubricant has been proven to be untrue. A normal charge of mineral oil left in the A/C system after a retrofit to R-134a will not damage the system. Mineral oil, however, does not mix well with R-134a, and will not provide adequate lubrication. Tests on both the orifice tube and TXV systems show that the mineral oil parks in places such as the accumulator, and does not appreciably affect performance or damage the system. The retrofit service bulletin will specify the correct oil to be used. It is important that this oil recommendation be followed carefully. RESIDUAL R-12 Residual R-12 left in a system, due to improper retrofit service procedures, may result in system damage unless the residual R-12 is kept below the 2 percent limit specified by the Society of Automotive Engineers' Specification J-1661. New service methods are being developed to minimize the level of R-12 remaining in the A/C system after the retrofit procedure is completed. Following these new procedures will be critical to insure that the above limits are met. SYSTEM FLUSHING R-11, a material commonly used as an A/C system flushing solvent, has been found to be chemically incompatible with PAG lubricant. Technicians should be aware that residual R-11 remaining in an R-12 system will be very damaging if the vehicle is retrofitted to R-134a later in its life. For many years GM has recommended the use of in-line filters as an alternative to system flushing. SYSTEM FLUSHING, USING EITHER R-11 OR ANY OTHER FLUSHING MATERIAL, IS NOT APPROVED BY GM FOR ANY A/C SYSTEM. DESICCANT PROTECTION Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 331226 > Jan > 94 > A/C - Retrofitting R-12 Vehicles to R-134A > Page 5247 It has been reported that the desiccant (moisture absorption material) used in 1992 and older R-12 A/C systems is incompatible with R-134a and PAG oil. The older desiccant was designed specifically for R-12 systems, but testing has shown that it is NOT necessary to replace the older desiccant just because the vehicle is being retrofitted to R-134a. 1993 and newer GM vehicles use desiccant designed to be compatible with both R-12 and R-134a systems. The amount of desiccant used in most GM vehicles is designed to last for at least seven years. To help maintain adequate protection for vehicles that must be retrofitted, it is recommended that the accumulator/dryer, which contains the desiccant, be replaced if the vehicle is more than five years old. "O" RINGS While continuing to service with R-12, be sure to use "O" rings and seal materials which are compatible with R-134a and PAG oil. This practice will eliminate concern in case the vehicle requires retrofitting later in its life. All "O" rings and seal materials available from GMSPO are compatible with R-134a systems. RETROFITTED SYSTEM PERFORMANCE Currently, it appears that for most GM vehicles, the retrofit procedure will require minimal changes to the existing system. Some vehicles may need additional parts and/or procedures to provide acceptable performance and/or durability. Our testing has shown that vehicles that have undergone recommended retrofit procedures will, in most climatic conditions, be minimally affected in terms of A/C performance. SERVICE POLICY Basic service policy is as follows: During Warranty - If an R-12 produced vehicle A/C system must be repaired or recharged under warranty, repairs will be completed using R-12. If R-12 is unavailable or unaffordable, GM will notify the dealer body and will pay for the warranty repair and the retrofit to R-134a. NOTE: It a customer requests that an in-warranty vehicle be converted to R-134a, and the R-12 system is functioning properly, the customer will be expected to pay for the retrofit. Out of Warranty - The cost of the conversion will be the responsibility of the customer. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 922501A > Aug > 92 > A/C - Use of Alternate Refrigerants In CFC 12 Refrigerant: Technical Service Bulletins A/C - Use of Alternate Refrigerants In CFC 12 Number: 92-250-1A Section: 0A Date: AUGUST 1992 Corporate Bulletin No.: 231205 ASE No.: A7 Subject: USE OF ALTERNATE REFRIGERANTS IN CFC 12 REFRIGERANT MOBILE AIR CONDITIONERS Model and Year: GALL MODEL YEARS - ALL PASSENGER CARS AND TRUCKS INCLUDING GEO A number of inquiries have been received concerning the use of "alternate refrigerants" as a replacement for R-12 refrigerant in General Motors air conditioning systems. Regardless of any advertised claims, there are currently no substitutes for refrigerant R-12 approved by General Motors. At the present time, only new or recycled R-12 is approved for use in General Motors R-12 air conditioning systems. Based on studies performed to date, the use of "alternate refrigerants" in General Motors R-12 air conditioning systems may result in higher system pressures, higher leak rates or incompatibility with drying and sealing materials. System performance and reliability may also be affected. Service equipment manufacturers have indicated that cross-contaminating R-12 recovery/recycling equipment with "alternate refrigerants" may damage the equipment. General Motors supports the Society of Automotive Engineers recommended service procedures for recovery and recycling of R-12. The use of known "alternate refrigerants" without proper service practices for identifying vehicle systems containing these "alternate refrigerants" and dedicated recovery equipment to service those vehicles will contaminate the recycled supply of R-12 refrigerant. Contamination of the recycled R-12 refrigerant makes the refrigerant unusable for recharging air conditioning systems and could jeopardize the recycling program. At the present time, General Motors has not approved any "alternate refrigerant" for R-12 in R-12 air conditioning systems. Therefore, R-12 systems should continue to be serviced with new or recycled R-12 only. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5252 Refrigerant: Technical Service Bulletins A/C Refrigerant - Contamination File In Section: 1 - HVAC Bulletin No.: 43-12-23 Date: September, 1994 Subject: Contaminated A/C Refrigerant Models: 1994 and Prior Passenger Cars and Trucks with R12 Air Conditioning Systems Government regulations limit the production of R12 refrigerant, commonly referred to as Freon, during 1994/1995 and restrict manufacture of new R12 material effective January 1, 1996. As R12 prices rise and supplies are depleted, it is anticipated non-approved substitute refrigerants and/or poor quality R12 material sold as new or reprocessed may become more prevalent. The Mobile Air Conditioning Society (MACS) recently expressed concern over reports of the sale of R12 refrigerant containing as high as 15% contamination by R22, a refrigerant commonly used in stationary home systems but unsuitable for use in mobile units. GM dealers should be careful to protect against contaminating their existing supplies of R12 or the A/C systems in customers' vehicles they service by dealing with reputable suppliers. All R12 refrigerant purchased for warranty repairs should be purchased through GM SPO to ensure GM quality standards are met. The use of non-approved R12 refrigerant substitutes, some of which contain flammable materials, has also been reported by MACS. These products are available to "do-it-yourselfers" who, in many cases, believe they are harmless replacements for the small cans of R12 used so commonly in the past. Once added to the A/C system, the vehicle can no longer be serviced using R12 recovery/recycling equipment without: - Risking permanent damage to recovery/recycling equipment - Contaminating the previously recovered R12 material in the recovery tank - Spreading the contamination when the recovered material is used to charge other vehicles or - Possible loss of the recovered material if the contaminated level is high enough to activate the air purge system Contaminated refrigerant also impacts customer satisfaction through poor vehicle A/C performance and loss of A/C system compressor/component durability. System or component failure resulting from the use of refrigerant which does not meet GM specification is not covered by the "New Vehicle Warranty". Unfortunately, there is no simple method to identify if a "do-it-yourselfer" or repair shop has added to or recharged a system with a non-approved refrigerant. The inability to protect against the spread of contaminated refrigerant threatens the recycling program and the industry's desire to maximize use of the remaining R12 supply. Beginning in 1993, General Motors STG, Harrison Division, Research Labs and Kent-Moore worked in conjunction with suppliers of various technologies to develop a tester to identify contaminated refrigerant in vehicle A/C systems before recovery. During development of the technology, several dealer service manager focus group studies were conducted to identify design features to best suit dealership needs. The discussions and surveys clearly indicated the desire for a dedicated instrument, permanently mounted to the refrigerant recovery cart to ensure ALL vehicles are automatically tested prior to recovering refrigerant. Testing ALL refrigerant for contamination prior to recovery is the ONLY means to ensure customer satisfaction, protect recovery equipment and avoid unintentional venting of refrigerant by your dealership. General Motors has evaluated all available technology for this project and only the J 39851 R12 "Pureguard" meets General Motors' specifications. The J 39851 R12 Pureguard Refrigerant Monitor has been classified as an essential tool and will be shipped by Kent-Moore to your dealership beginning in September of 1994. The essential price of the R12 "Pureguard" is $561 (for Canadian dealers the price is $800 Canadian). If your dealership has multiple R12 recovery equipment, additional units may be ordered from Kent-Moore for $561 at 1-800-345-2233. Features of the R12 "Pureguard" include: - Universally mounts to R12 Recovery Equipment - Automatically interrupts power to the Recovery Equipment when contaminated refrigerant is identified - Fully automatic design does not require technician action, training or interpretation - LCD displays Pureguard functions Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5253 - Meets GM contamination sensitivity requirements - Self calibrating - Micro-processor controlled - Audio alarm alerts technician Other Refrigerant Identifiers are being advertised which may be available this A/C season. However, ONLY the Kent-Moore J 39851 R12 "Pureguard" meets General Motors' current specifications which ensure recovered refrigerant is compatible with General Motors vehicles and General Motors approved recovery systems. An R134a Pureguard Refrigerant Identifier is currently under development and is anticipated to be available in early 1995. The contamination of R134a refrigerant is not expected to be a concern until the program to retrofit R12 vehicles to R134a becomes more widely used. Future bulletins will be issued to address the recovery and disposal of contaminated refrigerant. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5254 Technical Service Bulletin # 431207E Date: 970101 A/C - Retrofitting R-12 to R-134a File In Section: 1 - HVAC Bulletin No.: 43-12-07E Date: January, 1997 INFORMATION Subject: Guidelines for Retrofitting R-12 Vehicles to R-134a Models: 1984-94 Passenger Cars and Trucks (See List Below) This bulletin is being revised with the following changes: 1. Addition of all remaining GM vehicles, as listed. 2. Format rearranged for easier use. Please discard Corporate Bulletin Number 43-12-07D (Section 1 - HVAC). Car/Truck Platform Coverage Starts: 1984 - A, B, D, E, F, J, K, P, Y Carlines 1985 - C, M, N, R, S Carlines 1986 - H Carline 1987 - L, V (Allante) Car lines; M/L, G, R/V, S/T, P Truck lines 1988 - T (LeMans), E (Reatta), W Car lines; C/k, MED. Duty Truck lines 1989 - Tracker 1990 - U Van Vehicles Not Covered: T (Chevette and T1000), G RWD, C RWD, and X Car If a vehicle is not covered in the list above, GM's recommendation is that the vehicle continue to be serviced with R-12. This bulletin outlines the detailed retrofit procedures, as well as providing background information on many components and procedures. It is important to follow the bulletin, since each car and truck line has unique parts and procedures. However, the basic procedure is simple, and will become easier as you complete more retrofits. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5255 Retrofit Requirements The customer should be reminded that there is NO requirement in the U.S. to retrofit any vehicle produced with R-12. Vehicles built with R-12 can be serviced with R-12 as long as it is available (except in certain Canadian Provinces). GM has taken steps to extend the supply of R-12 and recommends that all R-12 vehicles continue to be serviced with R-12 as long as it is available. Training Video Before doing a retrofit the first time, it is recommended that you view the Certified Plus Training Video, Program number 51010.15, "R-134a Retrofit for GM Cars and Trucks". Table of Contents A. Retrofit Procedure 1. Inspect Condition of Vehicle 2. Recover the R-12 (new method) 3. Install the service port conversion fittings 4. Install any additional parts needed 5. Evacuate and recharge with new PAG or V5 retrofit oil and R-134a 6. Install the retrofit label Platform Details Compressor Replacement Chart B. General Information 1. Performance 2. Leakage 3. Desiccant 4. Improved Cooling Performance 5. PAG or V5 Oil Compatibility 6. Refrigerant Oil Level Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5256 C. Parts Information D. Warranty Information 1. Vehicle Still in Warranty 2. Customer Paid' Retrofitting Costs 3. Labor Time Information Notes on Retrofit Important: Before proceeding with any retrofit, make sure you have all component Parts required on hand to perform a proper and complete repair with Minimal downtime. R-12 Removal Prior to Retrofit To prepare a system for retrofitting, the R-12 must be recovered and the system must be completely evacuated. Evacuation is necessary to insure that small amounts of R-12 and air remaining in the system are removed. This will prevent cross contamination of the two refrigerants, which could lead to reduced A/C system reliability and performance. It is very important that the specified times for waiting after recovery and evacuation not be reduced. This time is required to sufficiently remove residual R-12 from the oil in the system. A considerable amount of testing has determined that the following procedure is required to achieve satisfactory results and conform to SAE J 1661: 1. Inspect Condition of Vehicle Install the gauge set on the high and low side ports. Use normal diagnostic procedures to find the cause of the vehicle's reported condition. One of three conditions will exist with the refrigerant system: a. System pressure correct, no leaks - proceed to Step 2 (Recovery). This would normally apply when: 1. The system must be recovered/recharged for a repair to a system other than the A/C system, or 2. Where the A/C system condition did not involve leaks, but requires recovery/recharge to replace a component. b. Compressor not operating, but some charge. Leak test to find the leak, complete Step 2 (Recovery), then correct the leak before proceeding with Step 3 (Conversion port installation). c. No charge in system - proceed with the Conversion port installation in Step 3. Use the ACR4 to evacuate for 5 minutes. If the leak can be heard, repair the leak. If the leak cannot be heard, charge with 1/2 pound of R-134a. Leak test with the J 39400 Leak Detector, recover the R-134a, repair any additional leaks found, and proceed with the evacuation in Step 5. 2. Recover the R-12 from the System Notice: THIS PROCEDURE IS DIFFERENT THAN THE NORMAL (NON-RETROFIT) RECOVERY PROCEDURE. R-12 will be recovered through the HIGH SIDE SERVICE PORT ONLY, WITH THE ENGINE RUNNING. Recovery through the low side will not effectively remove the R-12 from the accumulator, resulting in possible damage to the retrofitted system. Important: Vehicle must be above 50° F (10° C) to allow for complete recovery of the R-12. If it is not, either allow it to warm up in the shop overnight, or increase the evacuation time in Step 5.a to 30 minutes. a. Connect the recovery hose from the R-12 recovery cart (ACR3) to the middle port of the A/C gauge set. Open the oil drain valve on the ACR3 cart long enough to drain the oil. Failure to do so could cause excessive amounts of oil to build up in the separator, resulting in damage to the recovery cart compressor. b. Start the engine. Leave the hood up, and the windows open. On vehicles with manual A/C controls, set the A/C controls to normal A/C mode, high blower, and temperature control to full cold. On cars with automatic A/C controls, set the temperature to 75° F, "AUTO" mode, and manually select high blower. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5257 Make sure the vehicle compressor is engaged. Turn the cart on and start the recovery cycle. OPEN ONLY THE HIGH SIDE VALVE ON THE GAUGE SET. The vehicle system should eventually shut the compressor off. If the low side pressure drops below 15 psi, and the compressor does not turn off, turn it off now (go to "VENT" or "ECON" mode), but leave the engine running and the blower on "high". c. After the recovery cart shuts off the first time, wait 5 minutes. If the pressure on either the high or the low side rises above 0 psi, restart the recovery process. After the second shutoff, wait 2 minutes. If the pressure again rises above 0 psi, restart, and after shutoff, again wait 2 minutes. The process can be stopped when the pressure does not rise above 0 psi after 2 minutes. The engine can be shut off at this time. d. Remove the R-12 reclaim hose and the gauge set from the vehicle. Any repairs needed should be done at this time. If any components other than the compressor are replaced, they should be installed dry, and no extra oil should be added. 3. Install the Service Port Conversion Fittings Important: For GEO vehicles, skip to Step 4. Fitting installation is covered in that step. For vehicles that require a HPCOS, see Step 4. Some of these vehicles use a specific combination fitting to mount the HPCOS, which includes the high side service port fitting and the HPCOS port. The low side fitting is installed as detailed below. See "Platform Details" for further information. Important: A new tool kit, P/N J 39500-250, has been released. This kit contains the following items: ^ J 39500-71 Oil Injection Bottle Conversion Kit (includes 3 12 oz bottles, an extender tube, caps, and fittings) ^ J 39500-275 Tool kit, including the following: (See Figure 2) - J 34611-A Double ended valve core remover - J 25498-A High side adapter fitting - J 38702 Deep valve core adapter fitting Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5258 - J 41265 Thread cleaning wire brush - J 41266 Low side port thread restorer - J 41267 High side port thread restorer - J 39037 High side octagon socket - J 41256 Low side octagon socket New low profile, quick connect couplers, J 39500-20A (High side), and J 39500-24A (Low side), have been released as essential tools, to attach to the ACR4 (see Figure 3). These are much smaller couplers than the existing ones, and will allow attachment to the port fittings in much tighter quarters. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5259 Select and install the proper R-134a fittings (shown in Figure 4) from the chart below, based on how the ACR4 couplers will attach. Also, remember to check for proper hood clearance with the conversion fittings. Try the straight fittings first. The two-piece high side fitting is used when the existing fitting is screwed into the pipe fitting (some 1992, and nearly all 1993 models, use these fittings). Use the 90° elbow if the straight fitting does not allow the ACR4 couplers to connect. Fitting Type High Side Low Side Straight 52467941 52467943 Straight Two-piece 52467324 N/A 90° Elbow 52469054 52469055 The fittings should be installed as follows: a. Remove the caps from the R-12 fittings. Remove any dirt or grease from the port threads using the thread cleaning wire brush, J 41265. Inspect the fittings for thread damage. If any damage is found, use the port thread restorer (J 41266 low side, J 41267 high side) to repair the thread. For the two-piece fitting, remove the existing R-12 fitting and discard it. Use tool J 38704A (previously released, not part of the above kit) to remove the fitting. Make sure to hold the line securely to prevent damage when removing the existing fitting. If the fitting cannot be removed easily, use the saddle clamp valve listed below and seal the R-12 port and cap permanently. b. Install the selected fitting onto the existing R-12 fitting. Leave the valve core in the straight fittings, and remove the valve core when using the 90° fittings. If the valve cores need to be removed at a later time, they can be removed with the straight conversion fittings in place. On the low side straight fitting, use the J 34611-A tool to remove the core pin in the conversion fitting, then remove the core valve from the original R-12 fitting. Always recover the charge before valve core removal. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5260 Use the octagon sockets on the straight fittings (J 39037 high side, and J 41256 low side). Torque the new fitting until it seats. The fitting should seat fully BEFORE reaching 11 N.m (8 lb ft). If 11 N.m (8 lb ft) of torque is reached and the fitting has not seated, it is probable that the threads have been damaged. In this case, remove the fitting and use the thread restorer listed above. Reinstall the fitting, adding one drop of a thread locking compound such as Loctite(R) 242. The fittings (except the two-piece) have a thread locking compound applied to the threads. This compound will set up enough to restrict removal of the fitting in about 15 minutes. The fittings can now be used to evacuate the system (see Step 5). An additional type of conversion port fitting has been developed. This fitting is called a saddle clamp valve (see Figure 5). It can be clamped directly on a metal refrigerant line, and will be used if the existing fitting is damaged or is inaccessible. A drop of a thread locking compound, such as Loctite(R) 242, should be used on each bolt to prevent the threads from loosening. The R134a saddle clamp valve part numbers are: If an existing R-12 service port is not used, it must be rendered inoperative. Place several drops of a thread locking compound, such as Loctite(R) 243, in the valve core, and onto the cap threads. Secure the cap and let it set for 15 minutes. 4. Install Any Additional Parts Needed See "Platform Details" after Step 6. If a vehicle is listed as a "Basic Retrofit", no additional parts are required (except for compressors, see the Compressor Replacement Chart at the beginning of Platform Details). If no parts are required, PROCEED TO STEP 5. Compressors Compressors do not need to be replaced as part of a normal retrofit, unless indicated in the Compressor Replacement Chart. An R-12 compressor that is operating properly can, in most cases, be left in the vehicle when it is retrofitted to R134a. However, if a compressor failure is the reason the vehicle is in for service, and the vehicle will be retrofitted, OR if a vehicle has already been retrofitted with R-134a and the compressor fails at some time in the future, new compressors for use with R-134a are available. See the GMSPO Parts Catalog for specific part numbers. DO NOT use a replacement R-12 compressor for any vehicle retrofitted to R-134a (unless it is the new "oil-less" design). See "Compressor Availability" at the end of the Compressor Replacement Chart. Accumulator /Dryer If the vehicle is more than 5 years old, the Accumulator/Dryer (A/D) should be replaced to ensure that moisture is removed from the system. See the instructions for proper A/D identification in General Information. High Pressure Cut-Off Switch (HPCOS) Most trucks, and some 1984-93 B and D cars, require that a HPCOS be added to protect the refrigerant system during long idles at high temperature. The HPCOS kit (P/N 15981985) contains the switch, wire harness, heat sealing splice connectors, switch "0" ring, and installation instructions. A saddle clamp adapter (P/N 15985307), or a special dual fitting, is mounted to the high pressure line, and provides the port to mount the switch. A drop of a Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5261 thread locking compound, such as Loctite(R) 242, should be used on each bolt of the saddle clamp to prevent the threads from loosening. Some vehicles produced during the second half of the 1993 model year will already have a factory installed HPCOS. Check the back of the compressor for this switch. If present, the above switch will not have to be added. 5. Evacuate the System, and Recharge with PAG or V5 Retrofit Oil and R-134a Newly designed low profile quick connect couplers for the ACR4, J 39500-20A and J 39500-24A, have been released. These should be installed before proceeding with the evacuation. See Step 3, and Figure 3. a. Connect the R-134a cart (ACR4) to the system. Open the coupler valves on the hoses so that the pressures can be read on the gauges. On the cart, open the HIGH SIDE VALVE ONLY. DO NOT OPEN THE LOW SIDE VALVE! Program the cart for a 15 minute evacuation. Important: If the vehicle has been at outside temperatures of less than 50° F (10° C), or at high altitudes (above 3000 ft), use a 30 minute evacuation to insure complete removal of the R-12. If the vacuum pump will not start and a "H-P" reading is indicated on the ACR4 display, loosen the fitting at the high side line connection to the ACR4 to relieve pressure in the line. Tighten the fitting after pressure has been relieved. DO NOT USE THE RECOVERY MODE TO RELIEVE LINE PRESSURE. b. Start the evacuation. For a proper evacuation, the cart must pull down to 28-29 in. Hg. at sea level (reduce by 1 in. for each 1000 ft above sea level). Check the low side gauge for proper vacuum level, to make sure the new fittings are operating properly. While the evacuation is being done, the Retrofit label can be filled out and installed (see Step 6). Important: If the compressor was replaced at the same time as this retrofit, and the new compressor was shipped with the correct amount of PAG oil already in it, DO NOT add any additional oil to the system! Go to Step D. If an "oil-less" compressor was installed, add oil in Step C. A new retrofit oil for use with V5 compressor vehicles has been released. This oil will be used ONLY for retrofitted vehicles in which the original V5 compressor is retained. IT WILL NOT BE USED IF A COMPRESSOR IS REPLACED AT THE TIME OF THE RETROFIT. Failure to use this oil may significantly shorten the useful life of the compressor. Important: If the V5 Retrofit oil is not available from GMSPO, the compressor MUST BE REPLACED! To summarize the correct retrofit oil usage: ^ Compressor replaced during retrofit - NO OIL ADDED if new compressor shipped with oil - 8 oz. of PAG oil (9 oz of PAG oil with V5 compressor) added if compressor shipped without oil ("oil-less" design) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5262 ^ PAG oil used for future service if needed (mark PAG on box on label, Figure 6). ^ HR6 or R4 original compressor RETAINED - add 8 oz FAG oil to system ^ V5 original compressor RETAINED - add 9 oz V5 Retrofit oil to system. If V5 Retrofit oil is not available from GMSPO, REPLACE THE COMPRESSOR. c. Based on the above chart, add oil if needed. Use the new oil bottle and the extended tube kit, J 39500-71. Fill the bottle with at least 10 oz of oil. Attach the new bottle to the back of the ACR4, and open the oil fill valve. Allow the correct amount of oil to be drawn into the system. DO NOT allow the oil level to drop below the end of the pickup tube. This will prevent any air from being drawn into the system. If any oil was removed during the R-12 recovery evacuation steps, DO NOT add additional oil to replace it. d. Determine the correct amount of R-134a to use. Check the existing label of the vehicle for the R-12 charge amount. Use the formula {(R12 x .9) - .25 lb = R-134a} to determine the correct charge. This can also be stated as: Take 90% of the R12 charge, and subtract 1/4 lb. Follow the directions for the ACR4 cart to recharge the system. At the end of the process, "CPL" will be displayed. Close the high side valve. e. Start the vehicle, turn on the A/C system, and confirm that pressures are within normal operating ranges, as shown in the 1994 Service Manual. The 1994 Service Manuals can be used as a reference for diagnosis and specification of retrofitted systems. On some vehicles with automatic A/C controls or low charge diagnostics, the A/C compressor may not engage if any diagnostic codes were set during the retrofit. Check to see if any codes were set in either the HVAC or Engine Control systems. If they were, clear the codes following the directions in the Service Manual. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5263 f. TO INSURE AN ACCURATE CHARGE AMOUNT, IT IS IMPORTANT TO CLEAR THE ACR4 OF ANY REMAINING REFRIGERANT. Close the high side coupler valve and remove the high side hose from the vehicle. Then, open both the high and low side valves on the ACR4. After the pressures on both gages are at low side pressure, close the low side coupler valve. See Step G below, then remove the low side hose from the vehicle. Shut off the engine. Install the service port caps on the new fittings. These serve as a seal and can prevent system leaks. g. In the unlikely event that the low side fitting leaks when the coupler is removed, use the following procedure: 1. Immediately reinstall the coupler on the fitting. 2. Find the valve core remover J 34611-A. 3. Remove the coupler. 4. Use the double-ended valve core remover to turn the valve core pin counter-clockwise until the leak stops. 5. Install the cap. If the leak was substantial or continued for an extended period of time, it is highly recommended to evacuate and recharge the system to insure proper performance. If there is any question, the system can be rechecked by repeating Step F. h. Leak test any new port fittings, adapters, or valves that were installed, and any joints that were opened or repaired during the retrofit process, using tool J 39400. 6. Install the Retrofit Label The retrofit label (P/N 21030857, roll of 250) has been developed following SAF specifications to insure a smooth transition from R-12 to R-134a, and to insure a professional approach to the retrofit and a quality repair. Following the instructions in this bulletin will insure that the retrofit meets the SAE standards. Fill in the new label using a typewriter or a ball-point pen (see Figure 6). Select a location for the label that will be easily visible. Some suggested areas are the radiator support panel, an area near the existing R-12 charge label, or a flat surface near the high or low side service ports. The area selected should be a clean, underhood, painted sheet metal surface, and should be degreased and wiped down with a non-petroleum based cleaner. Do not install the label on a rubber surface. Apply the label, then apply the clear overlay to the label. Do not remove, cover, or render unreadable the existing R-12 charge label. DO cover the R-12 refrigerant charge amount on the existing label with an indelible, preferably black, marker. Platform Details Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5264 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5265 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5266 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5267 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5268 FOR ALL VEHICLES EXCEPT GEO, see the "Compressor Replacement Chart" at the end of this section. Compressor replacement requirements ARE NOT LISTED in the platform details (except for application details), except as noted below for Y car and P and Medium Duty truck. Compressor Replacement Chart Important: It is important to check the date code on the compressor. Any vehicle may have had a compressor replaced either during or after the warranty period. The date code will determine whether or not the compressor must be replaced. Compressor Availability A new compressor for use with R-134a systems will be shipped with the correct amount of PAG oil installed (see "IMPORTANT" below). Do not add any additional oil in Step 5 of the retrofit procedure if a compressor is to be replaced with a new R-134a compressor at the same time the initial retrofit is Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5269 being done. Important: During 1996, "oil-less" compressors began to be serviced with NO added oil. New part numbers will be issued, and both the box and the compressor will be clearly marked to indicate that no oil is present. If you receive one of these newer compressors, simply add the normal amount of oil to the system in Step 5 of the retrofit procedure (8 oz of PAG oil, or 9 oz of PAG oil with V5 compressor). These "oil-less" compressors are compatible with EITHER R12 or R-134a. Geo Models Compressors DO NOT HAVE TO BE REPLACED as part of the retrofit. New compressors are shipped with enough oil to accommodate the entire A/C system. Do not add additional PAG oil to the system it the compressor is being replaced. 1985-88 Nova, 1989-93 Prizm (S) 1. Using the Service Manual, remove the following components in the order given: a. Receiver/dryer. b. Loosen evaporator to compressor (suction) pipe (to be reinstalled) c. 1985-92 only: Loosen compressor to condenser (compressor discharge) pipe (to be reinstalled). d. 1985-88 only: Service Valve & Extension Housing on compressor (to be installed). e. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High and low side adapter fittings (see Step 3 of the retrofit procedure for detailed installation instructions). c. 1985-88 only: Service Valve & Extension Housing on compressor using new 0-rings. Six small 0-rings and one large 0-ring are required. d. Evaporator to compressor (suction) pipe 0-ring. e. 1985-92 Compressor to condenser (discharge) hose 0-ring. f. Receiver/dryer and 0-rings. R-134a amount: 85-92 - 650 grams (1.43 lb) 93 - 700 grams (1.54 lb) PAG oil amount: 100 cc (3.0 oz) Parts Required: Receiver/dryer: 85-88 - 94855761 89-93 - 94855762 Adapter Fittings: Low Side - 94855760 High Side - 94855759 0-Rings: 85-88 Compressor - Small 0-rings (6 required) - 94857336 - Large 0-ring - 94857337 85-93 Receiver/Dryer (2) - 94845949 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5270 85-93 Suction hose - 94855765 85-92 Discharge hose - 94845943 1985-88 Sprint, 1989-93 Metro (M) 1. Using the Service Manual, remove the following components in the order given: a. Receiver/dryer. b. Evaporator to compressor (suction) pipe. c. Compressor to condenser (compressor discharge) pipe. d. Joint service connector on compressor (to be reinstalled). e. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High and low side adapter fittings (see Step 3 of the retrofit procedure for detailed installation instructions). c. Joint service connector to compressor. Use new 0-rings. Six small 0-rings and one large 0-ring are required. d. Evaporator to compressor (suction) pipe, and new 0-ring. e. Compressor to condenser (discharge) hose and new 0-ring. f. Receiver/dryer and 0-ring. R-134a amount: 500 grams (1.10 lb) PAG oil amount: 100 cc (3.0 oz) Parts Required: Receiver/dryer: 85-86 - 91172081 87-88 - 91172079 89-93 - 96068480 Adapter Fittings: Low Side - 91172092 85-88 - High Side - 91172094 89-93 - High Side - 52467941 0-Rings: Compressor - Small 0-rings (6 required) - 91172095 - Large 0-ring - 96068915 Receiver/Dryer (2) - 96068488 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5271 89-93 - Suction hose - 96068490 89-93 - Discharge hose - 96068489 Suction hose: 85-86 - 91172086 85-86 Dealer installed: 91172087 87-88 - 91172088 89-93 - w/turbo - 96069121 - w/o turbo - 91172089 Discharge hose: 85-86 - 91172082 85-86 Dealer installed: 91172083 87-88 - 91172084 89-93 - 96069024 1989-93 Tracker 1. Using the Service Manual, remove the following components in the order given: a. Receiver/dryer. b. Evaporator to compressor (suction) pipe. c. Compressor to condenser (compressor discharge) pipe. d. Joint service connector on compressor (to be reinstalled). e. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High and low side adapter fittings (see Step 3 of the Retrofit procedure for detailed installation instructions). c. Joint service connector to compressor. Use new 0-rings. Six small 0-rings and one large 0-ring are required. d. Evaporator to compressor (suction) pipe, and new 0-ring. e. Compressor to condenser (discharge) hose and new 0-ring. f. Receiver/dryer and 0-ring. R-134a amount: 550 grams (1.21 lb) PAG oil amount: 100 cc (3.0 oz) Parts Required: Receiver/dryer - 91172080 Adapter, Low Side - 91172092 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5272 Adapter, High Side - 91172093 0-Rings: Compressor - Small (6) - 91172095 Large - 96068915 Receiver/dryer (2) - 96068488 Suction hose - 96068490 Discharge hose - 96068489 Suction hose - 91172091 Discharge hose - 91172085 1985-89 Spectrum and 1990-93 Storm (R) 1. Using the Service Manual, remove the following components in the order given: a. Condenser (Storm) or radiator grille (Spectrum) (to be reinstalled). b. Triple switch (Storm) or dual pressure switch (Spectrum) (to be reinstalled). c. Receiver/dryer. d. Evaporator to compressor (suction) pipe. e. Check valve from high side service valve (discard). f. Compressor (only if being replaced). 2. Using the Service Manual, install the following components in the order given. Be sure to use new 0-rings whenever a refrigerant connection has been disconnected. a. Compressor (if being replaced). b. High side adapter fitting (see Step 3 of the retrofit procedure for detailed installation instructions). Low Side - Part of suction hose c. Evaporator to compressor (suction) pipe, and new 0-rings. d. Receiver/dryer and 0-rings. e. Triple switch or dual switch, and new 0-ring. f. Condenser or radiator grille. R-134a amount: 91 - 500 grams (1.10 lb) 92-93 - 600 grams (1.32 lb) PAG oil amount: 150 cc (4.50 oz) Parts Required: Receiver/dryer: 85-89 - 97104795 90-91 - 97104797 92-93 - 97104798 Adapter, High Side: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5273 85-89 - 97104794 90-93 - 97104793 Adapter, Low Side: Part of Hose Asm. 0-rings: Receiver/dryer 85-91 - 94154048 92-93 - 94461700 Switch/pipe - 94461902 Suction hose: 85-86: 1.5L - 97104799; 1.6L - 97104800 90-93: 1.6L - 97104801; 1.8L - 97104803 B. General Information Several items affecting the performance and durability of the system should be considered: 1. Performance When performed properly, the retrofit from R-12 to R-134a will have minimal effect on the system's performance in most climatic conditions found in the United States and Canada. 2. Leakage Experience has shown that most leakage in an A/C system is due to leaks at the joints, or through a small leak in a hose, usually at the coupling. The R-134a molecules are smaller than R-12, and a small leak may result in a faster loss of refrigerant with R-134a. Because of this, it is very important to leak check all vehicles using the J 39400 leak detector, BEFORE the retrofit is performed, and repair any leaks found. "0" rings and hoses used in most GM vehicles are compatible with R-134a and do not need replacement during a retrofit. "0" rings or hoses installed in previous repairs may have been of non-compatible materials if GM parts were not used and will be more likely to deteriorate and leak than the original equipment materials. All "0" rings and hoses available through GMSP0 are compatible with R-134a. Remember that the normal policy is to replace the "0" rings whenever a joint is opened for any reason. 3. Desiccant You may have heard that the currently used desiccant in the accumulator is not compatible with R-134a. Extensive testing has shown that it is, in fact, suitable for use with R-134a, once it has been in service in an R-12 system. The accumulator in these models will not have to be changed during the retrofit procedure, unless the vehicle is more than 5 years old. Vehicles more than 5 years old should have the A/D replaced to add new desiccant for proper system drying. In the event that an accumulator/dryer (A/D) needs to be replaced on a retrofitted system in the future, only A/D's with XH-7 desiccant should be used. The service parts for the 1993 vehicles contain only XH-7 desiccant. The parts for the 1992 and older vehicles may contain either XH-5 or XH-7. Parts containing XH-7 can be identified (see Figure 1) by 1) an "A" printed on the top of the A/D; or 2) if there is a label on top of the A/D, there will be a square with an "A" inside; or 3) if there is a time code and date printed on top of the A/D just under the "Harrison" logo, the A/D contains XH-7. A/D's containing XH-5 can still be used on R-12 vehicles. 4. Improved Cooling Performance There have been service bulletins issued in the past with information improving the cooling performance of existing R-12 systems. These bulletins can also be used to improve the performance of retrofitted vehicles in high ambient temperature climates. 5. PAG or V5 Oil Compatibility Contrary to information published to date outside of General Motors, mineral oil and PAG or V5 oil ARE chemically compatible. The mineral oil left in the system after reclaiming the R-12 can remain in the system with no harmful effects. However, the mineral oil will not mix with the R-134a, and so will not circulate and perform its lubricating function. Testing has shown that most of the mineral oil will eventually collect in the Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5274 accumulator. The system will operate properly as long as refrigerant charge amounts are strictly adhered to. 6. Refrigerant Charge Level The retrofit R-134a charge level is more critical than with R-12 systems. Overcharging may push the mineral oil out of the AID, and cause it to circulate as a liquid. This is more likely to result in compressor damage. Undercharging may lead to loss of performance. It is very important to clear the hoses during the charging operation, to insure that all the refrigerant is delivered to the vehicle A/C system. This is covered in Step 6D of the Retrofit Procedure. C. Parts Information Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5275 Important: All of the following parts are NOT NEEDED for a normal retrofit. Follow the bulletin procedures to determine which parts you need! Individual vehicle kits are not necessary, since most of the parts are generic and only a few parts are needed for most vehicles. GEO Parts are listed in "Platform Details." Parts are currently available from GMSPO. D. Warranty Information 1. Vehicle Still Within the Original New Vehicle Limited Warranty Period When GM models for the years listed in the bulletin require repairs to the refrigerant system and the vehicles are still covered under the New Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5276 Vehicle Limited Warranty, dealers are instructed to proceed as follows: Important: On vehicles equipped with A/C systems NOT produced by GM (i.e., rear A/C systems in van conversions), consult the manufacturer of that A/C system for retrofit guidelines. ^ Offer the customer the option of repairing and recharging the system with R12, or retrofitting after repair and recharging with R-134a at no additional charge. ^ Provide the owner with, and review the information contained in, the "Converting Your Auto Air Conditioning System to Use the New Refrigerant" brochure. (Brochure, Form GM-0011, can be ordered free of charge from GM Fulfillment HQ, Phone 1-800-269-5100). ^ Record the customer's choice on the repair order and, as with all properly completed repair orders, ask the customer to sign on the appropriate line acknowledging the repairs requested. ^ Under no circumstances should the retrofit to R-134a be performed unless the customer has had the option explained prior to repair. Once the vehicle has been retrofitted to R-134a, a significant expenditure would be incurred to go back to R-12, in the event the customer has changed his/her mind. THIS OFFER APPLIES ONLY TO VEHICLES REQUIRING A/C REFRIGERANT SYSTEM REPAIRS UNDER THE TERMS OF THE NEW VEHICLE LIMITED WARRANTY. It is not a special policy, and any existing deductibles still apply. This is simply an option being offered to the customer during the warranty period at this time. GM reserves the right to terminate this offer at any time. If the R-12 refrigerant system does not require discharging for a warranty repair, but the customer requests a retrofit to R-134a, the retrofit WOULD BE PERFORMED AT THE CUSTOMER'S EXPENSE, EVEN DURING THE WARRANTY PERIOD. 2. Customer Paid Retrofitting Costs If the customer requests a retrofit to R-134a, for a specific vehicle whose retrofit parts and procedures have been released in this bulletin, the customer would be expected to pay the costs to retrofit under the following conditions: ^ The vehicle is no longer covered by the terms of the New Vehicle Limited Warranty. ^ The vehicle is covered by warranty, but the repair covered under the warranty does not require evacuating and recharging the refrigerant system. 3. Labor Time Information For Vehicles Repaired Under Warranty: Use existing labor operations for correcting the original condition. The quantity of R-134a used should be charged to the normal labor operation (not D4500), just as if it were R-12. Use D4500, 0.3 HR., to charge for parts and labor, for all of the following items: ^ Additional time for recovery of R-12 to meet SAE standards; ^ Install high and low side service port converter fittings; ^ Add PAG or V5 retrofit oil; ^ Complete label information and install. Add 0.2 hours to D4500 for installation of the HPCOS. Use T5321, 0.3 HR., for the Pontiac Bonneville hood seal installation. ANY PARTS OR LABOR TIME OTHER THAN THOSE LISTED ABOVE SHOULD BE CHARGED TO THE REGULAR LABOR OPERATION CORRESPONDING TO THE ORIGINAL CONDITION THAT 1S BEING REPAIRED. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5277 Technical Service Bulletin # 631209 Date: 960501 A/C - R12 or R134a Service Recommendations File In Section: 1 - HVAC Bulletin No.: 63-12-09 Date: May, 1996 INFORMATION Subject: Service Issues for Vehicles with R12 or R134a Air Conditioning Systems Models: 1988-96 Passenger Cars and Trucks R12 Service Recommendations As you know, production of R12 refrigerant ceased on December 31, 1995. Although R12 will no longer be manufactured, there is a reserve supply of R12 available. This reserve, along with strict A/C repair service adherence to proper refrigerant recycling procedures, should assure continued availability to meet consumers' needs. R12 can and should continue to be used to service vehicles built with R12 A/C systems as long as it is available. If R12 is no longer available or affordable, a system retrofit utilizing R134a is recommended. R134a IS THE ONLY SUBSTITUTE REFRIGERANT RECOMMENDED BY GM FOR USE IN GM VEHICLE A/C SYSTEMS, AND THEN ONLY AFTER FOLLOWING THE PROPER RETROFIT PROCEDURES FOR THE SPECIFIC MODEL. All new vehicle manufacturers have chosen R134a for retrofit. One of the key reasons is to protect both the service industry and consumers from the high costs that would result from purchasing equipment necessary to service multiple refrigerants. This position also reduces the threat of recycled refrigerant contamination. GM currently offers a simple, low cost R12 to R134a retrofit on many of its late model, front wheel drive passenger cars. Dealers should discuss this capability with owners of these specific models, listed in Retrofit Corporate Bulletin # 43-12-07D, whenever a repair to the A/C refrigerant system is required. Early retrofit of these specific models will aid in prolonging availability of the R12 supply and provide dealer service technicians the opportunity to become more familiar with the proper procedures for performing a retrofit. Remember - R12 and R134a refrigerant are not interchangeable! They cannot be mixed together. In fact, despite the claims of some refrigerant manufacturers, no proposed R12 refrigerant substitute can be added to, mixed with or used to "top off" an R12 system. Under provisions of law covering the service of refrigerants, mixing dissimilar refrigerant products during service is prohibited. To Summarize GM R12 Service Policy 1. Service R12 vehicles with good quality new or recycled R12 as long as it is available. 2. Purchase R12 from a reliable supplier. GMSPO has a supply of high quality R12 available. Dealers are requested to use only R12 supplied by GMSPO for warranty repairs. This high quality refrigerant will insure system performance and avoid the possibility of introducing contaminated material into the customer's A/C system. 3. Carefully test recovered R12 using the PureGuard monitor. On recovery equipment not protected by the PureGuard, always test the recovery cylinder prior to recharging a vehicle A/C system. 4. Discuss the R12 to R134a retrofit option with owners of GM vehicles listed in Retrofit Corporate Bulletin # 43-12-07D. Provide owner with a copy of the pamphlet "Converting Your Auto Air Conditioning System to Use the New Refrigerant". 5. Become familiar with retrofit procedures and exercise care in the handling of dissimilar refrigerants to prevent contamination. R134A Service Recommendations When servicing a previously retrofitted vehicle, there is concern that if all of the R12 is not completely removed prior to the retrofit procedure, it could contaminate your R134a equipment and recovery tank when a subsequent A/C repair is performed. Although the number of retrofits being performed today is minimal, the volume will increase as R12 prices rise. GM Service Technology Group is in the process of field testing a new R134a refrigerant purity tester similar to the PureGuard R12 refrigerant tester you now use. This new tool will mount to your ACR4 R134a Recovery Recycle and Recharge cart and sample all R134a refrigerant prior to recovery. It is expected that testing of this tool will be completed this year. This new tool, the Pureguard 2, will also test vehicles and your recycle tank for air contamination, which is threatening A/C system performance. High levels of air have been found in the recovery tanks on a number of R12 and R134a recovery carts. Air contamination is caused by improper recovery Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5278 procedures and short-cutting refrigerant recycling times. Use the following procedure for testing and correcting air contamination in your A/C service equipment. 1. Make certain that the ACR4 equipment has not been used for at least 12 hours. It is recommended that the equipment be left in an area where the temperature will remain constant overnight to allow the temperature of the refrigerant in the tank to stabilize. 2. Record the surrounding air temperature next to the ACR4 refrigerant tank. Important: A major assumption is that the ambient air temperature next to the tank represents the refrigerant temperature in the tank. Failure to take care in measuring the temperature could result in unnecessary work. 3. Close both liquid (blue) and vapor (red) valves on the ACR4 tank. 4. Disconnect low side (blue) service hose from the back of the ACR4. 5. Slowly disconnect the tank vapor hose (red) from the back of the ACR4 and connect it to the low side service port. 6. Open the vapor (red) valve on the tank and record the tank pressure on the low side gage. 7. Restore hoses to the original position. 8. Referring to the Table, find the ambient temperature measured in Step 2. Compare the pressure reading from Step 6 to the "maximum allowable pressure". If the pressure reading from Step 6 is less than the "maximum allowable pressure", no further action is necessary. Important: The closer the tank pressure is to the desired tank pressure, the better the A/C system will perform. 9. If the pressure reading from Step 6 exceeds the maximum allowable pressure from the Table, open both tank valves and operate the ACR4 through 4 or 5 evacuation cycles. This will activate the automatic air purge to lower the tank pressure. Important: Station should not be connected to vehicle. 10. Repeat the tank pressure checking procedure the next day to determine if the pressure has been reduced to acceptable levels. If the tank pressure has been reduced but is not acceptable, cycle with ACR4 through more evacuation cycles and recheck the next day. Continue process until acceptable pressure is obtained. If the tank pressure is not reduced through the evacuation cycling, then Kent-Moore should be contacted at 1-800-345-2233. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Page 5279 Refrigerant: Specifications MAKE, YEAR & MODEL Kg. Oz. CHEVROLET 1992 Beretta, Corsica 1.2 42 1992-91 Caprice 1.4 50 1992-90 Lumina 1.0 36 1992-88 Camaro, Corvette 1.0 36 1992-86 Cavalier 1.0 36 1991-89 Beretta, Corsica 1.3 44 1990-86 Celebrity 1.1 40 1990-82 Caprice 1.6 54 1989-87 Spectrum 0.8 28 1988-87 Beretta, Corsica, Corvette 1.0 36 1988-85 Sprint 0.7 24 1988-83 Monte Carlo 1.6 54 1987-83 Camaro 1.4 48 Chevette 1.0 36 1986-85 Spectrum 0.7 24 1986-83 Impala, Malibu 1.6 54 1985-83 Cavalier, Celebrity, Corvette 1.3 44 Citation 1.3 44 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Oil Charge Data Table System System ................................................................................................................................................. ............................................................................ 8 oz Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5284 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL TYPE ^ R-12 refrigerant oil, 525 viscosity (See Note). NOTE: If vehicle has been converted to R-134a use PAG (Polyalkaline Glycol) synthetic refrigerant oil (GM Part No. 12345923) or equivalent. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > A/C High Pressure Cut-Out Switch Refrigerant Pressure Sensor / Switch: Locations A/C High Pressure Cut-Out Switch RH Front Of Engine RH front of engine, below generator Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > A/C High Pressure Cut-Out Switch > Page 5289 Refrigerant Pressure Sensor / Switch: Locations A/C Low Pressure Cut-Out Switch RH Front Of Engine RH front of engine, on LH end of A/C compressor Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5290 Refrigerant Pressure Sensor / Switch: Service and Repair 1. Discharge A/C system. 2. Remove retaining ring using suitable snap ring pliers, then the control valve or switch. 3. Remove and discard O-rings. 4. Coat replacement O-rings with clean refrigerant oil, then seat O-rings in proper grooves in housing. 5. Lubricate control valve or switch with clean refrigerant oil, then press into place. 6. Install retaining ring with high point of curved sides toward switch or valve housing, ensuring that ring is fully seated. 7. Evacuate and recharge system, then check for leaks. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Temperature Sensor > Component Information > Locations Refrigerant Temperature Sensor: Locations RH Front Of 3.1L RH Front Of Engine Compartment, On A/C Line Applicable to: 1L/V6-192 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations LH Front Of Dash, On Relay Bracket Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations RH Side Of Engine Compartment. RH Rear Of Engine Compartment, Behind Strut Tower Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5301 Compressor Clutch Relay: Description and Operation Wiring Diagram For A/C Clutch Control The ECM controls the A/C compressor clutch relay. When the A/C is turned on, the ECM delays the clutch engagement to allow the IAC valve to raise the engine idle speed to compensate for the added load. The ECM allows the relay to disengage the A/C clutch at wide open throttle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Description and Operation Air Conditioning Switch: Description and Operation A/C "ON" Signal This signal indicates that the A/C control switch is turned "ON" and the pressure switch is closed. The computer uses this signal to adjust the idle speed, and on some models engages the A/C compressor clutch. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > A/C High Pressure Cut-Out Switch Refrigerant Pressure Sensor / Switch: Locations A/C High Pressure Cut-Out Switch RH Front Of Engine RH front of engine, below generator Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > A/C High Pressure Cut-Out Switch > Page 5310 Refrigerant Pressure Sensor / Switch: Locations A/C Low Pressure Cut-Out Switch RH Front Of Engine RH front of engine, on LH end of A/C compressor Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5311 Refrigerant Pressure Sensor / Switch: Service and Repair 1. Discharge A/C system. 2. Remove retaining ring using suitable snap ring pliers, then the control valve or switch. 3. Remove and discard O-rings. 4. Coat replacement O-rings with clean refrigerant oil, then seat O-rings in proper grooves in housing. 5. Lubricate control valve or switch with clean refrigerant oil, then press into place. 6. Install retaining ring with high point of curved sides toward switch or valve housing, ensuring that ring is fully seated. 7. Evacuate and recharge system, then check for leaks. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Locations Refrigerant Temperature Sensor: Locations RH Front Of 3.1L RH Front Of Engine Compartment, On A/C Line Applicable to: 1L/V6-192 Engine. 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Technical Service Bulletins > A/C - Refrigerant Loss Prevention Service Port HVAC: Technical Service Bulletins A/C - Refrigerant Loss Prevention Number: 91-284-1A Section: 1A Date: APRIL 1991 Corp. Bulletin No.: 971202R Subject: AIR CONDITIONING REFRIGERANT LOSS DUE TO LOOSE OR MISSING ACCESS FITTING CAPS Model and Year: 1980-91 PASSENGER CARS AND TRUCKS All GM air conditioning Hi side and Low side access fittings are supplied with a black plastic cap and seal assembly which provides the primary refrigerant seal for the service fittings. If the cap and seal assembly is missing or loose, a significant amount of refrigerant may leak through the valve core located in the access fitting, which could result in poor A/C performance or failure. When servicing any vehicle's A/C system, make sure all access fitting cap seals (refer to Figure) are in place and tight. Caps should be threaded on until contact with the "O" ring seal is made and then tightened another 1/4 - 1/2 turn to ensure proper sealing. High Side Low Side Valve - Cap and Seal Valve - Cap and Seal P/N 52451233 P/N 6551640 Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Technical Service Bulletins > Page 5319 Service Port HVAC: Locations The high pressure charging valve is located either on the high pressure line or the muffler, and the low pressure charging valve is located either on the accumulator or low pressure line. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Locations Vacuum Reservoir HVAC: Locations LH Front Of Engine Compartment, Below Battery Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling the SIR System Air Bag(s) Arming and Disarming: Service and Repair Disabling the SIR System The diagnostic energy reserve module (DERM) can maintain voltage to cause a system deployment for up to ten minutes after the ignition switch is turned off and the battery is disconnected. Servicing the SIR system during this period may result in accidental deployment and personal injury. 1. Ensure front wheels are pointed straight ahead. 2. Turn ignition switch to Lock position and remove SIR or AIRBAG fuse. 3. Remove lower left sound insulator. 4. Remove connector position assurance (CPA) lock and disconnect yellow two-way SIR harness connector at base of steering column. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling the SIR System > Page 5329 Air Bag(s) Arming and Disarming: Service and Repair Enabling the SIR System 1. Connect yellow two-way SIR harness connector and install CPA lock. 2. Install left sound insulator. 3. Install SIR fuse. 4. Turn ignition switch to Run position and ensure ``Inflatable Restraint'' lamp flashes 7-9 times and then remains off. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > Customer Interest for Malfunction Lamp / Indicator: > 83-81-34 > Mar > 99 > SIR - Operating Vehicle with Warning Light On Malfunction Lamp / Indicator: Customer Interest SIR - Operating Vehicle with Warning Light On File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-34 Date: March, 1999 INFORMATION Subject: Operating Vehicle with Supplemental Inflatable Restraint (SIR) Warning Light Illuminated Models: 1999 and Prior Passenger Cars and Light Duty Trucks with SDM Controlled Air Bag System The AIR BAG warning light is the key to driver notification of Supplemental Inflatable Restraint (SIR) system malfunctions. When the warning light remains illuminated or continues to flash, one or more of the following conditions may occur if vehicle operation is continued. ^ Non-deployment of the air bags in the event of a crash. ^ Deployment of the air bags without a crash. ^ Deployment of the air bags in crashes less severe than intended. If an AIR BAG warning light is illuminated or flashing, you should advise the customer of these possibilities and that the vehicle should be serviced right away. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Malfunction Lamp / Indicator: > 83-81-34 > Mar > 99 > SIR - Operating Vehicle with Warning Light On Malfunction Lamp / Indicator: All Technical Service Bulletins SIR - Operating Vehicle with Warning Light On File In Section: 8 - Chassis/Body Electrical Bulletin No.: 83-81-34 Date: March, 1999 INFORMATION Subject: Operating Vehicle with Supplemental Inflatable Restraint (SIR) Warning Light Illuminated Models: 1999 and Prior Passenger Cars and Light Duty Trucks with SDM Controlled Air Bag System The AIR BAG warning light is the key to driver notification of Supplemental Inflatable Restraint (SIR) system malfunctions. When the warning light remains illuminated or continues to flash, one or more of the following conditions may occur if vehicle operation is continued. ^ Non-deployment of the air bags in the event of a crash. ^ Deployment of the air bags without a crash. ^ Deployment of the air bags in crashes less severe than intended. If an AIR BAG warning light is illuminated or flashing, you should advise the customer of these possibilities and that the vehicle should be serviced right away. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling the SIR System Air Bag(s) Arming and Disarming: Service and Repair Disabling the SIR System The diagnostic energy reserve module (DERM) can maintain voltage to cause a system deployment for up to ten minutes after the ignition switch is turned off and the battery is disconnected. Servicing the SIR system during this period may result in accidental deployment and personal injury. 1. Ensure front wheels are pointed straight ahead. 2. Turn ignition switch to Lock position and remove SIR or AIRBAG fuse. 3. Remove lower left sound insulator. 4. Remove connector position assurance (CPA) lock and disconnect yellow two-way SIR harness connector at base of steering column. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling the SIR System > Page 5356 Air Bag(s) Arming and Disarming: Service and Repair Enabling the SIR System 1. Connect yellow two-way SIR harness connector and install CPA lock. 2. Install left sound insulator. 3. Install SIR fuse. 4. Turn ignition switch to Run position and ensure ``Inflatable Restraint'' lamp flashes 7-9 times and then remains off. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Top Teather Attachment Kits Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Top Teather Attachment Kits Bulletin No.: 99-09-40-004a Date: April 12, 2005 INFORMATION Subject: Top Tether Hardware Package for Child Restraint Seats Models: 1989-2002 Passenger Cars, Light Duty Trucks and Multi-Purpose Passenger Vehicles (Except EV1 and Prizm) Supercede: This bulletin is being revised to add the 2000-2002 model years. Please discard Corporate Bulletin Number 99-09-40-009 (Section 09 - Restraints). Important: GM of Canada and IPC Dealers are not authorized to utilize this service bulletin. Beginning in August, 1997 General Motors began providing Child Restraint Seat Top Tether Hardware Packages to customers in the United States who requested them. The Top Tether Hardware Package contains the necessary hardware for anchoring a forward facing child restraint seat top tether. One Child Restraint Seat Top Tether Hardware Package will be provided per vehicle to the retail customer at no charge for installation. Charges for installation of additional Top Tether Hardware Packages per vehicle are the responsibility of the customer. Most forward facing child restraint seats (CRS) sold in the United States prior to calendar year 1999 were not sold with top tether straps, but have provisions for them. Top tethers, which are required in Canada, can help to better secure the seat in the vehicle. When a forward facing CRS including a top tether is used, specially designed components must be used to secure the child seat top tether. These components are included in the Hardware Package from GMSPO. Top tethers are not normally required or used with rearward facing infant restraint seats. Rearward facing infant restraint seats should never be secured in the front seat of an air bag equipped vehicle unless the vehicle is equipped with an air bag de-activation (shut-off) switch and the switch has been used to turn the air bag off. Should a retail customer request installation of a Tether Hardware Package at the time of sale or delivery, it is to be installed at no charge to the owner. The labor to install a Tether Hardware Package prior to delivery of a new vehicle to the customer is considered to be part of the delivery "get ready process", and as such, is not claimable. Claiming for the cost and applicable handling allowance of the proper Tether Hardware Package used in the installation is allowed. If the customer requests installation of a Tether Hardware Package some time after delivery, the package is to be provided free of charge. Hardware Packages include installation instructions which are easily followed and can be installed by most customers. However, should the customer request the dealership's assistance to install the Tether Hardware Package, it is to be installed at no charge to the customer and the labor may be claimed. All claims submitted for installation labor of an approved Tether Hardware Package must be supported by a signed customer work order. Additional Hardware Packages and installation charges are the responsibility of the customer. In addition, passenger vehicle deliveries, including vans and sport utilities for daily rental usage, may have one tether hardware package supplied. Additional packages are the owner's responsibility. Dealers may claim appropriate parts under these circumstances. Sufficient quantities of parts should be ordered in advance of the arrival of vehicles to avoid delays. Important: When installing a Child Restraint Seat Top Tether Hardware Package, follow the installation instructions included in the package. Additional information about specific mounting locations and installations may be available in the Seat Belt Section (Sections 9, 10-10, 10-11 or 10A) I of the appropriate Service Manual, or the Restraints section of SI. Any questions regarding this policy should be directed to your Area Manager, Parts or Service. Parts Information For Top Tether Hardware Package part numbers and usage, see Group 14.870 (passenger cars & U-van), or Group 16.710 (Light Duty Truck) of the appropriate GMSPO Parts Catalog. In addition, they can also be found in Accessories Group 21.042. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Top Teather Attachment Kits > Page 5362 Warranty Information The dealership will be reimbursed for the parts and labor, if applicable, through the submission of a regular warranty claim. All claims submitted must be supported by a signed customer work order. Purchase and installation of additional Hardware Packages is the responsibility of the customer. For Top Tether Hardware Packages installed in the United States, submit as a normal warranty claim using the labor operations and time allowances shown. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls: > NHTSA92V003000 > Jan > 92 > Recall 92V003000: Seat Belt Guide Loops Defect Seat Belt: Recalls Recall 92V003000: Seat Belt Guide Loops Defect THE FRONT DOOR SHOULDER BELT GUIDE LOOPS MAY BE CRACKED AND ARE NOT IN COMPLIANCE WITH FMVSS 208. THE SEAT OCCUPANT FACES INCREASED RISK OF INJURY IN THE EVENT OF A SUDDEN STOP OR ACCIDENT. INSTALL REINFORCING PLATES ON THE CRACKED SHOULDER BELT GUIDES. SYSTEM: SAFETY BELTS; FMVSS 208. DESCRIPTION OF VEHICLES: PASSENGER VEHICLES; 1991 GM "J" AND "W" MODEL CARS. 1991 BUICK REGAL 1991 CHEVROLET CAVALIER 1991 CHEVROLET LUMINA 1991 OLDSMOBILE CUTLASS 1991 PONTIAC GRAND PRIX 1991 PONTIAC SUNBIRD Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Customer Interest: > 331052 > Oct > 93 > Seat Belts - Install Rear Seat Child Comfort Guides Seat Belt: Customer Interest Seat Belts - Install Rear Seat Child Comfort Guides Group Ref.: Body Bulletin No.: 331052 Date: October, 1993 SUBJECT: IMPROVED COMFORT FOR SMALL REAR SEAT OCCUPANTS AND CHILDREN USING SHOULDER BELTS (INSTALL REAR SEAT CHILD COMFORT GUIDES) MODELS: 1989-93 BUICK SKYLARK 1989-93 CHEVROLET CAVALIER (EXCLUDING CONVERTIBLE) 1988-93 CHEVROLET CORSICA/BERETTA 1992-93 OLDSMOBILE ACHIEVA 1989-91 OLDSMOBILE CALAIS 1989-93 PONTIAC GRAND AM 1989-93 PONTIAC SUNBIRD (EXCLUDING CONVERTIBLE) Condition: Some owners of the above vehicles may comment on the rear seat shoulder belts resting on the neck of one or both of the rear seat passengers, particulary those of small adults or children. Correction: This condition can be corrected by installing rear seat child comfort guides on the vehicle. 1. Remove the rear seat cushion and seat back. Refer to the procedures in Section 10-10 of the appropriate Service Manual. 2. Cut out the appropriate template that is included with the guide kit. 3. Position the template on the plastic quarter trim panel as shown in the information included in the guide kit. 4. Carefully drill a 1/4" hole through the quarter trim panel only. 5. Position the rear seat shoulder belt guide assembly to the previously drilled hole and snap the fastener into place. 6. Follow steps 3-5 for the opposite side of the vehicle. 7. Install the rear seat cushion and seat back. Refer to the procedures in Section 10-10 of the appropriate Service Manual. Parts Information: Parts are currently available from GMSPO. For vehicles repaired under warranty, use: Labor Operation Number: T3386 Labor Time: .5 hr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 331052 > Oct > 93 > Seat Belts - Install Rear Seat Child Comfort Guides Seat Belt: All Technical Service Bulletins Seat Belts - Install Rear Seat Child Comfort Guides Group Ref.: Body Bulletin No.: 331052 Date: October, 1993 SUBJECT: IMPROVED COMFORT FOR SMALL REAR SEAT OCCUPANTS AND CHILDREN USING SHOULDER BELTS (INSTALL REAR SEAT CHILD COMFORT GUIDES) MODELS: 1989-93 BUICK SKYLARK 1989-93 CHEVROLET CAVALIER (EXCLUDING CONVERTIBLE) 1988-93 CHEVROLET CORSICA/BERETTA 1992-93 OLDSMOBILE ACHIEVA 1989-91 OLDSMOBILE CALAIS 1989-93 PONTIAC GRAND AM 1989-93 PONTIAC SUNBIRD (EXCLUDING CONVERTIBLE) Condition: Some owners of the above vehicles may comment on the rear seat shoulder belts resting on the neck of one or both of the rear seat passengers, particulary those of small adults or children. Correction: This condition can be corrected by installing rear seat child comfort guides on the vehicle. 1. Remove the rear seat cushion and seat back. Refer to the procedures in Section 10-10 of the appropriate Service Manual. 2. Cut out the appropriate template that is included with the guide kit. 3. Position the template on the plastic quarter trim panel as shown in the information included in the guide kit. 4. Carefully drill a 1/4" hole through the quarter trim panel only. 5. Position the rear seat shoulder belt guide assembly to the previously drilled hole and snap the fastener into place. 6. Follow steps 3-5 for the opposite side of the vehicle. 7. Install the rear seat cushion and seat back. Refer to the procedures in Section 10-10 of the appropriate Service Manual. Parts Information: Parts are currently available from GMSPO. For vehicles repaired under warranty, use: Labor Operation Number: T3386 Labor Time: .5 hr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > NHTSA92V003000 > Jan > 92 > Recall 92V003000: Seat Belt Guide Loops Defect Seat Belt: All Technical Service Bulletins Recall 92V003000: Seat Belt Guide Loops Defect THE FRONT DOOR SHOULDER BELT GUIDE LOOPS MAY BE CRACKED AND ARE NOT IN COMPLIANCE WITH FMVSS 208. THE SEAT OCCUPANT FACES INCREASED RISK OF INJURY IN THE EVENT OF A SUDDEN STOP OR ACCIDENT. INSTALL REINFORCING PLATES ON THE CRACKED SHOULDER BELT GUIDES. SYSTEM: SAFETY BELTS; FMVSS 208. DESCRIPTION OF VEHICLES: PASSENGER VEHICLES; 1991 GM "J" AND "W" MODEL CARS. 1991 BUICK REGAL 1991 CHEVROLET CAVALIER 1991 CHEVROLET LUMINA 1991 OLDSMOBILE CUTLASS 1991 PONTIAC GRAND PRIX 1991 PONTIAC SUNBIRD Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 331052 > Oct > 93 > Seat Belts - Install Rear Seat Child Comfort Guides Seat Belt: All Technical Service Bulletins Seat Belts - Install Rear Seat Child Comfort Guides Group Ref.: Body Bulletin No.: 331052 Date: October, 1993 SUBJECT: IMPROVED COMFORT FOR SMALL REAR SEAT OCCUPANTS AND CHILDREN USING SHOULDER BELTS (INSTALL REAR SEAT CHILD COMFORT GUIDES) MODELS: 1989-93 BUICK SKYLARK 1989-93 CHEVROLET CAVALIER (EXCLUDING CONVERTIBLE) 1988-93 CHEVROLET CORSICA/BERETTA 1992-93 OLDSMOBILE ACHIEVA 1989-91 OLDSMOBILE CALAIS 1989-93 PONTIAC GRAND AM 1989-93 PONTIAC SUNBIRD (EXCLUDING CONVERTIBLE) Condition: Some owners of the above vehicles may comment on the rear seat shoulder belts resting on the neck of one or both of the rear seat passengers, particulary those of small adults or children. Correction: This condition can be corrected by installing rear seat child comfort guides on the vehicle. 1. Remove the rear seat cushion and seat back. Refer to the procedures in Section 10-10 of the appropriate Service Manual. 2. Cut out the appropriate template that is included with the guide kit. 3. Position the template on the plastic quarter trim panel as shown in the information included in the guide kit. 4. Carefully drill a 1/4" hole through the quarter trim panel only. 5. Position the rear seat shoulder belt guide assembly to the previously drilled hole and snap the fastener into place. 6. Follow steps 3-5 for the opposite side of the vehicle. 7. Install the rear seat cushion and seat back. Refer to the procedures in Section 10-10 of the appropriate Service Manual. Parts Information: Parts are currently available from GMSPO. For vehicles repaired under warranty, use: Labor Operation Number: T3386 Labor Time: .5 hr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > NHTSA92V003000 > Jan > 92 > Recall 92V003000: Seat Belt Guide Loops Defect Seat Belt: All Technical Service Bulletins Recall 92V003000: Seat Belt Guide Loops Defect THE FRONT DOOR SHOULDER BELT GUIDE LOOPS MAY BE CRACKED AND ARE NOT IN COMPLIANCE WITH FMVSS 208. THE SEAT OCCUPANT FACES INCREASED RISK OF INJURY IN THE EVENT OF A SUDDEN STOP OR ACCIDENT. INSTALL REINFORCING PLATES ON THE CRACKED SHOULDER BELT GUIDES. SYSTEM: SAFETY BELTS; FMVSS 208. DESCRIPTION OF VEHICLES: PASSENGER VEHICLES; 1991 GM "J" AND "W" MODEL CARS. 1991 BUICK REGAL 1991 CHEVROLET CAVALIER 1991 CHEVROLET LUMINA 1991 OLDSMOBILE CUTLASS 1991 PONTIAC GRAND PRIX 1991 PONTIAC SUNBIRD Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 5403 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 5409 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power > Page 5415 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 91858A > Oct > 90 > Electrical Connectors Service Procedure Multiple Junction Connector: All Technical Service Bulletins Electrical Connectors - Service Procedure Number: 91-85-8A Section: 8A Date: October 1990 Corp. Bulletin No.: 018115 Subject: PROCEDURE FOR CHECKING CONNECTOR TERMINAL CONTACT Model and Year: 1982-91 PASSENGER CARS AND TRUCKS Figure 1 TO: ALL CHEVROLET DEALERS Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 91858A > Oct > 90 > Electrical Connectors Service Procedure > Page 5420 When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit J 38125-4 instruction manual for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: "Check for poor connection or replace...". Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually to underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, see Figure 1, causing an open or intermittently open circuit. Follow the procedure below to check terminal contact. 1. Separate the connector halves, refer to Terminal Repair Kit J 38125-4 instruction manual. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals causing high terminal resistance, intermittent connection or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety, terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit J 38125-2, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit J 38125-2, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question, refer to Terminal Repair Kit J 38125-2. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power > Page 5426 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 91858A > Oct > 90 > Electrical Connectors Service Procedure > Page 5431 When diagnosing an electrical system that utilizes Metri-Pack 150/280/480/630 series terminals (refer to Terminal Repair Kit J 38125-4 instruction manual for terminal identification), it is important to check terminal contact between a connector and component, or between in-line connectors, before replacing a suspect component. Frequently, a diagnostic chart leads to a step that reads: "Check for poor connection or replace...". Mating terminals must be inspected to assure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually to underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact, see Figure 1, causing an open or intermittently open circuit. Follow the procedure below to check terminal contact. 1. Separate the connector halves, refer to Terminal Repair Kit J 38125-4 instruction manual. 2. Inspect the connector halves for contamination. Contamination will result in a white or green build-up within the connector body or between terminals causing high terminal resistance, intermittent connection or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety, terminals, seals and connector body. 3. Using an equivalent male terminal from the Terminal Repair Kit J 38125-2, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact will require a certain amount of force to separate the terminals. 4. Using an equivalent female terminal from the Terminal Repair Kit J 38125-2, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the good female terminal, and then joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question, refer to Terminal Repair Kit J 38125-2. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Below RH Side Of Front Seat Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Technical Service Bulletins > Recalls for Seat Belt Guide Track: > NHTSA92V003000 > Jan > 92 > Recall 92V003000: Seat Belt Guide Loops Defect Seat Belt Guide Track: Recalls Recall 92V003000: Seat Belt Guide Loops Defect THE FRONT DOOR SHOULDER BELT GUIDE LOOPS MAY BE CRACKED AND ARE NOT IN COMPLIANCE WITH FMVSS 208. THE SEAT OCCUPANT FACES INCREASED RISK OF INJURY IN THE EVENT OF A SUDDEN STOP OR ACCIDENT. INSTALL REINFORCING PLATES ON THE CRACKED SHOULDER BELT GUIDES. SYSTEM: SAFETY BELTS; FMVSS 208. DESCRIPTION OF VEHICLES: PASSENGER VEHICLES; 1991 GM "J" AND "W" MODEL CARS. 1991 BUICK REGAL 1991 CHEVROLET CAVALIER 1991 CHEVROLET LUMINA 1991 OLDSMOBILE CUTLASS 1991 PONTIAC GRAND PRIX 1991 PONTIAC SUNBIRD Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Guide Track: > NHTSA92V003000 > Jan > 92 > Recall 92V003000: Seat Belt Guide Loops Defect Seat Belt Guide Track: All Technical Service Bulletins Recall 92V003000: Seat Belt Guide Loops Defect THE FRONT DOOR SHOULDER BELT GUIDE LOOPS MAY BE CRACKED AND ARE NOT IN COMPLIANCE WITH FMVSS 208. THE SEAT OCCUPANT FACES INCREASED RISK OF INJURY IN THE EVENT OF A SUDDEN STOP OR ACCIDENT. INSTALL REINFORCING PLATES ON THE CRACKED SHOULDER BELT GUIDES. SYSTEM: SAFETY BELTS; FMVSS 208. DESCRIPTION OF VEHICLES: PASSENGER VEHICLES; 1991 GM "J" AND "W" MODEL CARS. 1991 BUICK REGAL 1991 CHEVROLET CAVALIER 1991 CHEVROLET LUMINA 1991 OLDSMOBILE CUTLASS 1991 PONTIAC GRAND PRIX 1991 PONTIAC SUNBIRD Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > Warnings and Alarm - Update Test Procedure Seat Belt Reminder Lamp: Technical Service Bulletins Warnings and Alarm - Update Test Procedure Number: 91-301-8A Section: 8A Date: MAY 1991 Corporate Bulletin No.: 138108 Subject: WARNINGS AND ALARM UPDATE TEST PROCEDURE Model and Year: 1990-91 CAVALIER SUBJECT UPDATE 1990 and 1991 ALL J CARLINES 1. The Fasten Belts Indicator test needs to be updated to reflect a fault in the Automatic Safety Belt circuit. If the Fasten Belts indicator remains lit after performing test "D" in Section 8A-76, check for an opening in the 528 ckt between term "B" of the Multi-Function Alarm Module and splice S237. 2. The circuit operation for the Fasten Belts Indicator needs to include the statement: The Fasten Belts indicator will remain lit if there is a fault in the Automatic Safety Belt circuit. Please note your copies of the above Service Manuals. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Testing and Inspection > Test D: Fasten Belts Indicator Test Fig. 17 Automatic Safety Belt Diagnosis, Fasten Belts Indicator Test Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Testing and Inspection > Test D: Fasten Belts Indicator Test > Page 5458 Fig. 18 Automatic Safety Belt Diagnosis, Indicator Short Test Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Locations > Safety Belt Lap Retractor Solenoid Seat Belt Retractor: Locations Safety Belt Lap Retractor Solenoid In Lower Rear Of Each Front Door Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Locations > Safety Belt Lap Retractor Solenoid > Page 5463 Seat Belt Retractor: Locations Safety Belt Shoulder Retractor Solenoid In Upper Rear Of Each Front Door Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Below RH Side Of Front Seat Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Power Antenna Mast - Replacement Antenna Mast: Technical Service Bulletins Power Antenna Mast - Replacement Group Ref.: Accessories Bulletin No.: 439604 Date: April, 1994 SUBJECT: POWER ANTENNA MAST REPLACEMENT MODELS: 1991-94 PASSENGER CARS (EXCEPT GEO) On most GM vehicles with a power antenna option, it is not necessary to replace the entire power antenna assembly if the mast becomes damaged. The mast can be ordered separately (see the GMSPO Parts Catalog for specific applications). Mast installation instructions are included with the service package. WARRANTY INFORMATION: For vehicles repaired under warranty, use: Labor Operation: R0420 Use published labor operation time. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Tools - Keyless Entry Transmitter Tester Keyless Entry Transmitter: Technical Service Bulletins Tools - Keyless Entry Transmitter Tester File In Section: 9 - Accessories Bulletin No.: 83-90-12 Date: August, 1998 INFORMATION Subject: Essential Tool J 43241 Remote Keyless Entry and Passive Keyless Entry Transmitter Tester Models: 1990-99 Passenger Cars and Trucks with Remote Keyless Entry or Passive Keyless Entry Systems A new essential tool, J 43241 Remote Keyless Entry Transmitter Tester, has been sent to all GM Dealers. This tester can be used on all RKE and PKE systems, on past as well as current models. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Tools - Keyless Entry Transmitter Tester > Page 5484 Important: Before using the tester and the diagnostic chart, the following two steps must be performed. 1. Verify that the keyless entry transmitter is the correct model for the vehicle remote system. An incorrect model transmitter may pass this test, but may not activate the vehicle remote system. The correct transmitter can usually be identified by part number. 2. Ensure that the transmitter is synchronized with the vehicle (if applicable). Refer to Transmitter Synchronization in the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Telephone/Mobile Radio - Install/Troubleshooting Technical Service Bulletin # 83-96-05 Date: 980701 Radio Telephone/Mobile Radio - Install/Troubleshooting File In Section: 9 - Accessories Bulletin No.: 83-96-05 Date: July, 1998 Subject: Radio Telephone/Mobile Radio (Transceiver) Installation and Troubleshooting Guidelines Models: 1990-99 Passenger Cars and Trucks This bulletin cancels and supercedes bulletin 34-92-12. Please discard Corporate Bulletin Number 34-92-12 (Section 9 - Accessories). The following information is being provided to assist in the installation and troubleshooting of Radio Telephone/Mobile Radios. Certain radio telephones or land mobile radios (also known as Radio Transceivers), or the way in which they are installed, may adversely affect various vehicle operations such as engine performance, driver information, entertainment and electrical systems. Expenses incurred to protect the vehicle systems from any adverse effect of any such installation are NOT the responsibility of General Motors Corporation. The following are general guidelines for installing a radio transceiver in General Motors vehicles. These guidelines are intended to supplement, but not to be used in place of, detailed instructions which are the sole responsibility of the manufacturer of the involved radio transceiver. Although this document refers to passenger vehicles, the same general guidelines apply to trucks. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Telephone/Mobile Radio - Install/Troubleshooting > Page 5489 EMC TROUBLESHOOTING CHART 1. Transceiver Location Refer to the attached figures during installation. 1. Transceiver Location Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Telephone/Mobile Radio - Install/Troubleshooting > Page 5490 a. One piece transceivers should be mounted under the dash, or on the transmission hump where they will not interfere with vehicle controls or passenger movement (See Figure 1 - One Piece Transceiver Installation). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Telephone/Mobile Radio - Install/Troubleshooting > Page 5491 b. Locate the transceiver for remote radios on the driver's side of trunk as near to the vehicle body side as possible (See Figure 2 - Trunk Mount Transceiver Installation). Caution: To avoid possible serious injury, do not mount any transceivers, microphones, speakers, or any other item In the deployment path of a Supplemental Inflatable Restraint (SIR) or "Air Bag". 2. Antenna Installation a. Each vehicle model reacts to radio frequency energy differently. It is suggested that a magnetic-mount antenna be used to check the proposed antenna location for unwanted effects on the vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Telephone/Mobile Radio - Install/Troubleshooting > Page 5492 Antenna location is a major factor in these effects. b. The antenna should be a permanent-mount type, located in the center of the roof or center of the rear deck lid. If a magnet-mount antenna is used, care should be taken to mount the antenna in the same location as a permanent-mount type. If a disguise-mount antenna is used, great care should be taken to shield (using copper tape, etc.) any tuning network from vehicle electronics and wiring, or mount the tuning network in an area completely clear (6 inches or 15 cm away) of vehicle electronics and wiring. c. Standard metal mount antennas may be mounted on a vehicle with non-metallic body panels by two methods: 1. Mount the antenna near a metal frame section and bond the antenna mount to the frame with a short metal strap, which will provide the ground plane connection. 2. Some antenna manufacturers may offer "Ground Plane Kits" that consist of self adhesive metal foil that may be attached to the body panel to provide a ground plane connection. d. Glass Mount Antennas Glass mounted antennas should be kept as high as possible in the center of the rear window or windshield, between rear window defrost "grid lines", if present. Some vehicles use glass that contains a thin metallic layer for defrosting, or to control solar gain. GLASS MOUNT ANTENNAS WILL NOT FUNCTION WHEN MOUNTED ON THIS TYPE OF GLASS. 3. Antenna Cable Routing a. Always use high quality coax cable (95% shield coverage minimum), located away (at least 6 inches or 15 cm) from ECM's, PCM's and other electronic modules. b. Care should be taken to maintain as great a distance as possible between any vehicle wiring and coax cable. 4. Antenna Tuning It is important that the antenna be tuned properly and that reflected power be kept to less than 10% (VSWR less than 2:1) at all operating frequencies. Important: High VSWR has been shown to contribute/cause interference problems with vehicle systems. 5. Radio Wiring and Power Lead Connection Locations a. Methods to connect radio power on General Motors vehicles is dependent on the vehicle model (See Figure 1 - One Piece Transceiver Installation or Figure 2 - Trunk Mount Transceiver Installation as needed). Do not connect the negative power lead to any under-dash termination point. One of the following four methods is suggested: 1. Connect the positive and negative power leads directly to the battery terminals. GM approved methods of connecting auxiliary wiring include the adapter package illustrated in Figure 4 - Power Cable Battery Connections. Important: It is recommended that a fuse be placed in the transceiver negative power lead. This is to prevent possible transceiver damage in the event the battery to engine block ground lead is inadvertently disconnected. 2. Connect the positive lead to the auxiliary power terminal (usually identified by a red plastic cover in the underhood area). Connect the negative lead directly to the negative battery terminal. Important: See above important statement regarding fusing the negative power lead. 3. Connect the positive lead to the auxiliary power terminal (usually identified by a red plastic cover in the underhood area). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Telephone/Mobile Radio - Install/Troubleshooting > Page 5493 Connect the negative lead to the battery body connection point (usually identified by a short # 10 AWG or larger wire running from the negative battery terminal to the body of the vehicle). Important: See above important statement regarding fusing the negative power lead. 4. Connect the positive and negative leads to the Special Equipment Option (SEO) wiring provided for this purpose (if vehicle has this option). b. For One Piece Transceivers (See Figure 1 - One Piece Transceiver Installation) When ignition switch control is desired, and no SEO wiring exists, a 12 volt power contactor must be installed in the transceiver positive power lead (See Figure 3 - Power Contactor Wiring). The contactor (supplied by the installer) should be located near a proper 12 volt feed source. One lead of the contactor coil should be connected through an appropriate in-line fuse to an available accessory circuit or ignition circuit not Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Telephone/Mobile Radio - Install/Troubleshooting > Page 5494 powered during engine cranking. The return lead of the contactor coil must return to a proper fused negative point. c. Handset or Control Units 1. Any negative power lead from a handset or control unit must return to a properly fused negative connection point. 2. It is preferable that the positive power lead for a handset, or control unit, be connected directly to a properly fused positive power feed point. If ignition switch control is desired, the handset or control unit positive power lead may be connected through an appropriate in-line fuse to an available accessory circuit (or ignition circuit not powered during engine cranking). 3. It is recommended that the handset or control unit positive and negative power leads be appropriately fused separately from the transceiver positive and negative power leads. d. Multiple Transceivers or Receivers If multiple transceivers or receivers are to be installed in the vehicle, power leads to the trunk or under the dash should be connected to covered, insulated terminal strips. All transceivers or receivers may then have their power leads connected to the insulated terminal strips. This makes a neater installation and reduces the number of wires running to the vehicle underhood area. Both positive and negative power leads should be fused. 6. Radio Wire Routing (See Figure 1 - One Piece Transceiver Installation, or Figure 2 - Trunk Mount Transceiver Installation as needed). a. The power leads (fused) should be brought through a grommeted hole (provided by the installer) in the front cowl. For trunk mounted transceivers, the cables should continue on along the driver's side door sills, under the rear seat and into the trunk through a rear bulkhead. Maintain as great a distance as possible between radio power leads and vehicle electronic modules and wiring. b. If the radio power leads need to cross the engine compartment, they should cross between the engine and the front of the vehicle. Troubleshooting Refer to the Troubleshooting Chart as needed. 1. Most vehicle-radio interaction is avoided by following the Installation Guidelines outlined above. 2. If vehicle-radio interaction is evident following radio installation, the source of the problem should be determined prior to further vehicle/radio operation. The EMC Troubleshooting Chart should help in determining the source of the vehicle-radio interaction. Parts Information P/N Description 1846855 Adapter Kit, Side Terminal Battery (consisting of Adapter Terminal, Terminal Cover, Wire Connector, Insulation Boot) 12004188 Bolt, Battery Cable Terminal 12354951 Spacer, Battery Cable Terminal Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest for Compact Disc Player (CD): > 649601 > Jan > 97 > Compact Disc Players - CD Changer Loading Procedures Compact Disc Player (CD): Customer Interest Compact Disc Players - CD Changer Loading Procedures File In Section: 9 - Accessories Bulletin No.: 64-96-01 Date: January, 1997 INFORMATION Subject: Compact Disc Players - Procedures for Correct Use and Maintenance Models: 1997 and Prior Passenger Cars and Trucks CD Changer Loading Procedures Because of differences in CD changer loading procedures, some confusion exists regarding this issue. Although correct loading procedures are included with each changer's Owner's Manual, often this information is not available to the dealer service personnel. Verify proper loading when evaluating customer concerns of "CD inoperative". Delco Electronics Product Type Loading Procedure Radio w/intergral CD label side up 6 disc changer (LLAI) label side up 10 disc changer (FMI) label side up 12 disc changer (LLAI) label side down Important: Failure to load magazine/player correctly will disable the operation. Important: Only the 12 disc changer is to be loaded with the label side down. CD Cleaners Avoid use of commercially available CD cleaners. The use of CD cleaners is not recommended and can damage the player's CD mechanism. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 649601 > Jan > 97 > Compact Disc Players - CD Changer Loading Procedures Compact Disc Player (CD): All Technical Service Bulletins Compact Disc Players - CD Changer Loading Procedures File In Section: 9 - Accessories Bulletin No.: 64-96-01 Date: January, 1997 INFORMATION Subject: Compact Disc Players - Procedures for Correct Use and Maintenance Models: 1997 and Prior Passenger Cars and Trucks CD Changer Loading Procedures Because of differences in CD changer loading procedures, some confusion exists regarding this issue. Although correct loading procedures are included with each changer's Owner's Manual, often this information is not available to the dealer service personnel. Verify proper loading when evaluating customer concerns of "CD inoperative". Delco Electronics Product Type Loading Procedure Radio w/intergral CD label side up 6 disc changer (LLAI) label side up 10 disc changer (FMI) label side up 12 disc changer (LLAI) label side down Important: Failure to load magazine/player correctly will disable the operation. Important: Only the 12 disc changer is to be loaded with the label side down. CD Cleaners Avoid use of commercially available CD cleaners. The use of CD cleaners is not recommended and can damage the player's CD mechanism. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Audio - Radio Frequency Interference (RFI) Diagnosis/ID Technical Service Bulletin # 349212R Date: 930701 General Information Bulletin Number: 93-9-10 Reference Number: 349212R Publish Date: 7/93 Subject: RADIO FREQUENCY INTERFERENCE IDENTIFICATION AND DIAGNOSIS Models Affected: 1993 AND PRIOR ALL MODELS The purpose of this information is to help in the identification and diagnosis of Radio Frequency Interference (RFI). RFI symptoms may include noises, interference, static, whines, pops. and poor reception of stations normally receivable by the radio system. These symptoms may also apply to any two-way communications radio installed in the vehicle including HAM, police, fire, business band and cellular phones. Radio Frequency Interference is the undesirable disturbance of an electrical system or device with another electrical system or device. The following charts will help identify: 1. If the symptoms are related to RFI, and 2. The source of the interference. It may be helpful to obtain a copy of the Delco Electronics Audio Systems Diagnostics Guide 1992 edition. This is a manual aimed at identifying, diagnosing, and repairing the radio system. This manual is available from STG; item # 19007.03-1. You may also want to consult your division's service bulletin concerning Radio Telephone Installation Guidelines. This information will identify the proper methods and routing for all installations of two-way communications devices. Questionnaire To begin diagnosing RFI, it is important to understand the nature of the condition and the elements that may be involved. The following questionnaire will help determine vital pieces of information for the diagnostic process. 1. Is the vehicle equipped with any non-factory installed electronics? (This includes: radar detectors, scanners, and hand held communications devices.) 2. If the condition occurs with a non-factory installed radio or telephone, have the Radio Installation Guidelines been followed? 3. Identify the frequencies affected. 4. If the concern is with the entertainment radio, is the tape or CD affected. 5. Identify when the condition occurs: Key off, Key in accessory, Key on engine not running, Engine running, Other - describe. 6. Is the condition intermittent or related to the operation of another electrical device in the vehicle? 7. If the condition is related to a fleet vehicle answer the following: a. Who installed the radio(s)? b. Were the GM installation guidelines followed? c. Is this the only vehicle that demonstrates this condition? d. Do similar vehicles have different antennas? e. Are the antennas mounted in the same location? See RFI Diagnostic Charts that follow. RFI Determination and Identifying Chart This chart is to be used along with the diagnostic charts to help determine if the condition is RFI related, and to help identify what electronic device in the vehicle is interfering with the radio. Make sure the information in the questionnaire is as accurate as possible. You MUST be able to duplicate the customer's condition to diagnose RFI concerns. The process of identifying RFI and the source of an interference is simply the process of elimination. When the source of the interference is disconnected from power, the radio will work properly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Audio - Radio Frequency Interference (RFI) Diagnosis/ID > Page 5513 Box 1 Verify that the condition is present, then disconnect any non-factory add-on electronics, (not including the radio) Box 2 If the condition goes away when a particular device is disconnected, reconnect the device to verify it as the source of the interference. If the condition is related to non-factory add-on electronics, consult the GM installation guidelines (See Box 6) as an example of how to add an electronic component to the vehicle's electrical system. Box 3 If the condition is ONLY present with the engine running, disconnect electrical components that are active only with the engine running. The charging system, various solenoids, and relays may be intermittently disconnected while observing the condition. In some cases a component cannot be disconnected while the engine is running. In these cases, the component can be tested independent of the vehicle (i.e. fuel injectors). For further tips on engine noise diagnostics refer to the Delco Sound Service Guide, Engine Noise Chart. Box 4 If the condition can be eliminated and the interference isolated to a component, determine if a bulletin has been published concerning this particular condition. Contact your Technical Assistance Group for additional information if no bulletins are found. Box 5 If the concern cannot be eliminated by testing in any key position and by disconnecting fuses and components, the condition most likely is not RFI. Refer to the Delco Sound Service Guide or the vehicle service manual for further diagnostic tips and check for any published bulletins. If the concern cannot be identified or eliminated, contact your Technical Assistance Group for further assistance. Box 6 The "Installation Guidelines for Aftermarket Accessories" for all model years and all trucks and carlines are located in the following Service Bulletin 91-8-2. Also, there may be separate installation guidelines for cellular phones. A search for service bulletins may be necessary to find these. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Audio - Radio Frequency Interference (RFI) Diagnosis/ID > Page 5514 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Audio - Radio Frequency Interference (RFI) Diagnosis/ID > Page 5515 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Audio - Radio Frequency Interference (RFI) Diagnosis/ID > Page 5516 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Audio - Radio Frequency Interference (RFI) Diagnosis/ID > Page 5517 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5527 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5528 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5529 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5535 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5536 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5537 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5546 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5547 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5548 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5554 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5555 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 5556 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Technical Service Bulletins > Recalls for Front Door Striker: > NHTSA91V165000 > Sep > 91 > Recall 91V165000: Door/Seat Belt Interlock Defect Front Door Striker: Recalls Recall 91V165000: Door/Seat Belt Interlock Defect FRONT DOOR INTERLOCK STRIKER MAY FAIL, CAUSING DOOR FRAME COLLAPSE AND INSUFFICIENT STRENGTH FOR THE SHOULDER BELT ANCHORAGE. THE DOOR FRAME WOULD COLLAPSE. VEHICLE DOES NOT COMPLY WITH FMVSS 210. REPLACE THE PASSIVE RESTRAINT INTERLOCK STRIKER STUDS ON FRONT DOORS. SYSTEM: SEAT BELT ANCHORAGE; FMVSS 210. VEHICLE DESCRIPTION: PASSENGER VEHICLES. 1991 CHEVROLET CAVALIER 1991 PONTIAC SUNBIRD Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Technical Service Bulletins > Recalls for Front Door Striker: > 91C24 > Sep > 91 > Recall - Front Door Interlock Striker Replacement Technical Service Bulletin # 91C24 Date: 910901 Recall - Front Door Interlock Striker Replacement Number: 91C24 Section: 10 Date: Sept., 1991 Subject: PRODUCT SAFETY CAMPAIGN 91C24 FRONT DOOR INTERLOCK STRIKER STUD Model and Year: 1991 CAVALIER (EXCEPT CONVERTIBLES) To: All Chevrolet Dealers The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to repair within sixty (60) 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 owner 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 to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the letter that is being sent to owners, the owners are being instructed to contact the Chevrolet Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration. DEFECT INVOLVED General Motors has determined that certain 1991 Chevrolet Cavalier model vehicles fail to conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 210, "Seat Belt Assembly Anchorages". If a vehicle crash should occur, the front door interlock striker stud may fail, which could cause the door frame to collapse. Collapse of the door frame could result in failure of the shoulder belt to provide sufficient restraint to the occupant. To prevent this condition from occurring, dealers are to replace the passive restraint interlock striker studs on involved vehicles. VEHICLES INVOLVED Involved are certain 1991 "J", vehicles built within the VIN breakpoints. Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign. These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. Owner, Dealer and Parts Information OWNER NOTIFICATION Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of owner letter included with this bulletin). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Technical Service Bulletins > Recalls for Front Door Striker: > 91C24 > Sep > 91 > Recall - Front Door Interlock Striker Replacement > Page 5592 DEALER CAMPATGN RESPONSIBILITY Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward. Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or it is in your dealership for service in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle. Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. This bulletin is notice to you that the new motor vehicles included in this campaign may not comply with the standard identified above. Under Section 108 of the National Traffic and Motor Vehicle Safety Act, 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 campaign correction, your dealership may be subject to a civil penalty up to $1000 for each such sale. PARTS INFORMATION Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2). Quantity/ Part Number Description Vehicle 22571850 Door Interlock Striker Stud 2 Service Procedure (PERFORM PROCEDURE ON BOTH FRONT DOORS OF INVOLVED VEHICLES) TOOLS REQUIRED: 9 mm hex head (allen head) driver - Thin-blade putty knife - Pointed drift or drift with a relatively small tip - Ball peen hammer (approx. 24 oz.) 1. Lower front door glass and remove plastic cover from shoulder belt upper guide loop anchor. See illustration. 2. Mask off inside surface of vertical leg of door frame to prevent damage to painted surfaces. See illustration. 3. Using a 9 mm hex driver, loosen interlock striker until there is a 2 mm gap between base of striker and the door frame. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Technical Service Bulletins > Recalls for Front Door Striker: > 91C24 > Sep > 91 > Recall - Front Door Interlock Striker Replacement > Page 5593 4. Strike loosened striker with hammer until stud is dislodged from door frame. NOTICE: The interlock striker stud is "press-fit" into the door frame, and several blows may be required to dislodge it. It is recommended that several moderate blows be used, rather than trying to dislodge the stud with one or two very heavy blows. Use of excessive force may result in damage to door frame. 5. Remove interlock striker. Do not discard striker as it will be re-installed on new interlock striker stud. 6. With door open, position tip of drift in depression at end of striker stud and finish driving stud out of door frame by striking drift with hammer. 7. Working from inside of door frame, carefully disengage run channel weatherstrip from door frame using a thin-blade putty knife to disengage upper clip. Upper clip is located about 1 inch above top edge of shoulder belt anchor. See illustration. 8. Carefully disengage enough of run channel weather strip from door frame to allow retrieval of interlock striker stud. It may be necessary to use a "magnet-on-a-stick", or needle nose pliers to retrieve stud. 9. Using needle-nose pliers, position replacement stud in hole in door frame, and install striker onto stud finger tight. Align base of stud so long edges of stud are parallel to channel in door frame (see illustration). Using a 9 mm hex driver, torque striker to 35 N-m (26 lb.ft.). Make sure new stud is pulled fully into hole, and that base of stud is flush against inside of door frame. 10. Push run channel weatherstrip back into door frame, making sure it is properly positioned for sealing and appearance. Be sure to re-engage upper run channel weatherstrip clip to door frame. 11. Re-install plastic cover to shoulder belt upper guide loop anchor. 12. Check window for proper up/down operation. 13. Remove masking tape. 14. Repeat above steps, 1-13 for opposite front door of vehicle. 15. Install Campaign Identification Label. Identification Label and Claim Information CAMPAIGN IDENTIFICATION LABEL Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign identification Label." Each label provides a space to include the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner. Additional "Campaign Identification Labels" can be obtained from DAC. Apply "Campaign Identification Label" only on a clean, dry surface. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Technical Service Bulletins > Recalls for Front Door Striker: > 91C24 > Sep > 91 > Recall - Front Door Interlock Striker Replacement > Page 5594 CLAIM INFORMATION Submit a Product Campaign claim with the information indicated. Dealers will automatically receive the correct labor and material allowance based on the labor operation performed. Refer to the Chevrolet Claims Processing Manual for details on Product campaign claim submission. Owner Letter September 30, 1991 Dear Chevrolet Cavalier Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. REASON FOR THIS RECALL General Motors has determined that certain 1991 Chevrolet Cavalier model Vehicles fail to conform to the requirements of Federal motor Vehicle Safety Standard (FMVSS) 210, "Seat Belt Assembly Anchorages". If a vehicle crash should occur, the front door interlock striker stud may fail, which could cause the door frame to collapse. Collapse of the door frame could result in failure of the shoulder belt to provide sufficient restraint to the occupant. WHAT WE WILL DO To prevent this condition from occurring, your Chevrolet dealer will replace the passive restraint interlock striker studs on the front doors of your Cavalier. This service will be performed for you at no charge. WHAT YOU SHOULD DO Please contact your Chevrolet dealer as soon as possible to arrange a service date and so the dealer may order the necessary parts for the repair. Instructions for making this correction have been sent to your dealer and parts are available. The labor time necessary to perform this service correction is approximately 25 minutes. Please ask your dealer if you wish to know hcw much additional time will be needed to schedule and process your vehicle. Your Chevrolet dealer is best equipped to obtain parts and provide service to ensure that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed service date, and they do not remedy this condition on that date or within five (5) days, we recommend you contact the Chevrolet Customer Assistance Center by calling 1-800-222-1020. After contacting your dealer and the Customer Assistance Center, if you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call 1-800-424-9393 (Washington D.C. residents use 366-0123). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Technical Service Bulletins > By Symptom for Front Door Striker: > NHTSA91V165000 > Sep > 91 > Recall 91V165000: Door/Seat Belt Interlock Defect Front Door Striker: By Symptom Recall 91V165000: Door/Seat Belt Interlock Defect FRONT DOOR INTERLOCK STRIKER MAY FAIL, CAUSING DOOR FRAME COLLAPSE AND INSUFFICIENT STRENGTH FOR THE SHOULDER BELT ANCHORAGE. THE DOOR FRAME WOULD COLLAPSE. VEHICLE DOES NOT COMPLY WITH FMVSS 210. REPLACE THE PASSIVE RESTRAINT INTERLOCK STRIKER STUDS ON FRONT DOORS. SYSTEM: SEAT BELT ANCHORAGE; FMVSS 210. VEHICLE DESCRIPTION: PASSENGER VEHICLES. 1991 CHEVROLET CAVALIER 1991 PONTIAC SUNBIRD Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Technical Service Bulletins > By Symptom for Front Door Striker: > 91C24 > Sep > 91 > Recall - Front Door Interlock Striker Replacement Technical Service Bulletin # 91C24 Date: 910901 Recall - Front Door Interlock Striker Replacement Number: 91C24 Section: 10 Date: Sept., 1991 Subject: PRODUCT SAFETY CAMPAIGN 91C24 FRONT DOOR INTERLOCK STRIKER STUD Model and Year: 1991 CAVALIER (EXCEPT CONVERTIBLES) To: All Chevrolet Dealers The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to repair within sixty (60) 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 owner 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 to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the letter that is being sent to owners, the owners are being instructed to contact the Chevrolet Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration. DEFECT INVOLVED General Motors has determined that certain 1991 Chevrolet Cavalier model vehicles fail to conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 210, "Seat Belt Assembly Anchorages". If a vehicle crash should occur, the front door interlock striker stud may fail, which could cause the door frame to collapse. Collapse of the door frame could result in failure of the shoulder belt to provide sufficient restraint to the occupant. To prevent this condition from occurring, dealers are to replace the passive restraint interlock striker studs on involved vehicles. VEHICLES INVOLVED Involved are certain 1991 "J", vehicles built within the VIN breakpoints. Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign. These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. Owner, Dealer and Parts Information OWNER NOTIFICATION Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of owner letter included with this bulletin). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Technical Service Bulletins > By Symptom for Front Door Striker: > 91C24 > Sep > 91 > Recall - Front Door Interlock Striker Replacement > Page 5604 DEALER CAMPATGN RESPONSIBILITY Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward. Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or it is in your dealership for service in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle. Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. This bulletin is notice to you that the new motor vehicles included in this campaign may not comply with the standard identified above. Under Section 108 of the National Traffic and Motor Vehicle Safety Act, 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 campaign correction, your dealership may be subject to a civil penalty up to $1000 for each such sale. PARTS INFORMATION Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2). Quantity/ Part Number Description Vehicle 22571850 Door Interlock Striker Stud 2 Service Procedure (PERFORM PROCEDURE ON BOTH FRONT DOORS OF INVOLVED VEHICLES) TOOLS REQUIRED: 9 mm hex head (allen head) driver - Thin-blade putty knife - Pointed drift or drift with a relatively small tip - Ball peen hammer (approx. 24 oz.) 1. Lower front door glass and remove plastic cover from shoulder belt upper guide loop anchor. See illustration. 2. Mask off inside surface of vertical leg of door frame to prevent damage to painted surfaces. See illustration. 3. Using a 9 mm hex driver, loosen interlock striker until there is a 2 mm gap between base of striker and the door frame. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Technical Service Bulletins > By Symptom for Front Door Striker: > 91C24 > Sep > 91 > Recall - Front Door Interlock Striker Replacement > Page 5605 4. Strike loosened striker with hammer until stud is dislodged from door frame. NOTICE: The interlock striker stud is "press-fit" into the door frame, and several blows may be required to dislodge it. It is recommended that several moderate blows be used, rather than trying to dislodge the stud with one or two very heavy blows. Use of excessive force may result in damage to door frame. 5. Remove interlock striker. Do not discard striker as it will be re-installed on new interlock striker stud. 6. With door open, position tip of drift in depression at end of striker stud and finish driving stud out of door frame by striking drift with hammer. 7. Working from inside of door frame, carefully disengage run channel weatherstrip from door frame using a thin-blade putty knife to disengage upper clip. Upper clip is located about 1 inch above top edge of shoulder belt anchor. See illustration. 8. Carefully disengage enough of run channel weather strip from door frame to allow retrieval of interlock striker stud. It may be necessary to use a "magnet-on-a-stick", or needle nose pliers to retrieve stud. 9. Using needle-nose pliers, position replacement stud in hole in door frame, and install striker onto stud finger tight. Align base of stud so long edges of stud are parallel to channel in door frame (see illustration). Using a 9 mm hex driver, torque striker to 35 N-m (26 lb.ft.). Make sure new stud is pulled fully into hole, and that base of stud is flush against inside of door frame. 10. Push run channel weatherstrip back into door frame, making sure it is properly positioned for sealing and appearance. Be sure to re-engage upper run channel weatherstrip clip to door frame. 11. Re-install plastic cover to shoulder belt upper guide loop anchor. 12. Check window for proper up/down operation. 13. Remove masking tape. 14. Repeat above steps, 1-13 for opposite front door of vehicle. 15. Install Campaign Identification Label. Identification Label and Claim Information CAMPAIGN IDENTIFICATION LABEL Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign identification Label." Each label provides a space to include the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner. Additional "Campaign Identification Labels" can be obtained from DAC. Apply "Campaign Identification Label" only on a clean, dry surface. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Technical Service Bulletins > By Symptom for Front Door Striker: > 91C24 > Sep > 91 > Recall - Front Door Interlock Striker Replacement > Page 5606 CLAIM INFORMATION Submit a Product Campaign claim with the information indicated. Dealers will automatically receive the correct labor and material allowance based on the labor operation performed. Refer to the Chevrolet Claims Processing Manual for details on Product campaign claim submission. Owner Letter September 30, 1991 Dear Chevrolet Cavalier Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. REASON FOR THIS RECALL General Motors has determined that certain 1991 Chevrolet Cavalier model Vehicles fail to conform to the requirements of Federal motor Vehicle Safety Standard (FMVSS) 210, "Seat Belt Assembly Anchorages". If a vehicle crash should occur, the front door interlock striker stud may fail, which could cause the door frame to collapse. Collapse of the door frame could result in failure of the shoulder belt to provide sufficient restraint to the occupant. WHAT WE WILL DO To prevent this condition from occurring, your Chevrolet dealer will replace the passive restraint interlock striker studs on the front doors of your Cavalier. This service will be performed for you at no charge. WHAT YOU SHOULD DO Please contact your Chevrolet dealer as soon as possible to arrange a service date and so the dealer may order the necessary parts for the repair. Instructions for making this correction have been sent to your dealer and parts are available. The labor time necessary to perform this service correction is approximately 25 minutes. Please ask your dealer if you wish to know hcw much additional time will be needed to schedule and process your vehicle. Your Chevrolet dealer is best equipped to obtain parts and provide service to ensure that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed service date, and they do not remedy this condition on that date or within five (5) days, we recommend you contact the Chevrolet Customer Assistance Center by calling 1-800-222-1020. After contacting your dealer and the Customer Assistance Center, if you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call 1-800-424-9393 (Washington D.C. residents use 366-0123). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Striker: > NHTSA91V165000 > Sep > 91 > Recall 91V165000: Door/Seat Belt Interlock Defect Front Door Striker: All Technical Service Bulletins Recall 91V165000: Door/Seat Belt Interlock Defect FRONT DOOR INTERLOCK STRIKER MAY FAIL, CAUSING DOOR FRAME COLLAPSE AND INSUFFICIENT STRENGTH FOR THE SHOULDER BELT ANCHORAGE. THE DOOR FRAME WOULD COLLAPSE. VEHICLE DOES NOT COMPLY WITH FMVSS 210. REPLACE THE PASSIVE RESTRAINT INTERLOCK STRIKER STUDS ON FRONT DOORS. SYSTEM: SEAT BELT ANCHORAGE; FMVSS 210. VEHICLE DESCRIPTION: PASSENGER VEHICLES. 1991 CHEVROLET CAVALIER 1991 PONTIAC SUNBIRD Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Striker: > 91C24 > Sep > 91 > Recall - Front Door Interlock Striker Replacement Technical Service Bulletin # 91C24 Date: 910901 Recall - Front Door Interlock Striker Replacement Number: 91C24 Section: 10 Date: Sept., 1991 Subject: PRODUCT SAFETY CAMPAIGN 91C24 FRONT DOOR INTERLOCK STRIKER STUD Model and Year: 1991 CAVALIER (EXCEPT CONVERTIBLES) To: All Chevrolet Dealers The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to repair within sixty (60) 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 owner 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 to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the letter that is being sent to owners, the owners are being instructed to contact the Chevrolet Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration. DEFECT INVOLVED General Motors has determined that certain 1991 Chevrolet Cavalier model vehicles fail to conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 210, "Seat Belt Assembly Anchorages". If a vehicle crash should occur, the front door interlock striker stud may fail, which could cause the door frame to collapse. Collapse of the door frame could result in failure of the shoulder belt to provide sufficient restraint to the occupant. To prevent this condition from occurring, dealers are to replace the passive restraint interlock striker studs on involved vehicles. VEHICLES INVOLVED Involved are certain 1991 "J", vehicles built within the VIN breakpoints. Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign. These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned. Owner, Dealer and Parts Information OWNER NOTIFICATION Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of owner letter included with this bulletin). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Striker: > 91C24 > Sep > 91 > Recall - Front Door Interlock Striker Replacement > Page 5616 DEALER CAMPATGN RESPONSIBILITY Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward. Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or it is in your dealership for service in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle. Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. This bulletin is notice to you that the new motor vehicles included in this campaign may not comply with the standard identified above. Under Section 108 of the National Traffic and Motor Vehicle Safety Act, 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 campaign correction, your dealership may be subject to a civil penalty up to $1000 for each such sale. PARTS INFORMATION Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2). Quantity/ Part Number Description Vehicle 22571850 Door Interlock Striker Stud 2 Service Procedure (PERFORM PROCEDURE ON BOTH FRONT DOORS OF INVOLVED VEHICLES) TOOLS REQUIRED: 9 mm hex head (allen head) driver - Thin-blade putty knife - Pointed drift or drift with a relatively small tip - Ball peen hammer (approx. 24 oz.) 1. Lower front door glass and remove plastic cover from shoulder belt upper guide loop anchor. See illustration. 2. Mask off inside surface of vertical leg of door frame to prevent damage to painted surfaces. See illustration. 3. Using a 9 mm hex driver, loosen interlock striker until there is a 2 mm gap between base of striker and the door frame. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Striker: > 91C24 > Sep > 91 > Recall - Front Door Interlock Striker Replacement > Page 5617 4. Strike loosened striker with hammer until stud is dislodged from door frame. NOTICE: The interlock striker stud is "press-fit" into the door frame, and several blows may be required to dislodge it. It is recommended that several moderate blows be used, rather than trying to dislodge the stud with one or two very heavy blows. Use of excessive force may result in damage to door frame. 5. Remove interlock striker. Do not discard striker as it will be re-installed on new interlock striker stud. 6. With door open, position tip of drift in depression at end of striker stud and finish driving stud out of door frame by striking drift with hammer. 7. Working from inside of door frame, carefully disengage run channel weatherstrip from door frame using a thin-blade putty knife to disengage upper clip. Upper clip is located about 1 inch above top edge of shoulder belt anchor. See illustration. 8. Carefully disengage enough of run channel weather strip from door frame to allow retrieval of interlock striker stud. It may be necessary to use a "magnet-on-a-stick", or needle nose pliers to retrieve stud. 9. Using needle-nose pliers, position replacement stud in hole in door frame, and install striker onto stud finger tight. Align base of stud so long edges of stud are parallel to channel in door frame (see illustration). Using a 9 mm hex driver, torque striker to 35 N-m (26 lb.ft.). Make sure new stud is pulled fully into hole, and that base of stud is flush against inside of door frame. 10. Push run channel weatherstrip back into door frame, making sure it is properly positioned for sealing and appearance. Be sure to re-engage upper run channel weatherstrip clip to door frame. 11. Re-install plastic cover to shoulder belt upper guide loop anchor. 12. Check window for proper up/down operation. 13. Remove masking tape. 14. Repeat above steps, 1-13 for opposite front door of vehicle. 15. Install Campaign Identification Label. Identification Label and Claim Information CAMPAIGN IDENTIFICATION LABEL Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign identification Label." Each label provides a space to include the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen. Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner. Additional "Campaign Identification Labels" can be obtained from DAC. Apply "Campaign Identification Label" only on a clean, dry surface. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Striker: > 91C24 > Sep > 91 > Recall - Front Door Interlock Striker Replacement > Page 5618 CLAIM INFORMATION Submit a Product Campaign claim with the information indicated. Dealers will automatically receive the correct labor and material allowance based on the labor operation performed. Refer to the Chevrolet Claims Processing Manual for details on Product campaign claim submission. Owner Letter September 30, 1991 Dear Chevrolet Cavalier Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. REASON FOR THIS RECALL General Motors has determined that certain 1991 Chevrolet Cavalier model Vehicles fail to conform to the requirements of Federal motor Vehicle Safety Standard (FMVSS) 210, "Seat Belt Assembly Anchorages". If a vehicle crash should occur, the front door interlock striker stud may fail, which could cause the door frame to collapse. Collapse of the door frame could result in failure of the shoulder belt to provide sufficient restraint to the occupant. WHAT WE WILL DO To prevent this condition from occurring, your Chevrolet dealer will replace the passive restraint interlock striker studs on the front doors of your Cavalier. This service will be performed for you at no charge. WHAT YOU SHOULD DO Please contact your Chevrolet dealer as soon as possible to arrange a service date and so the dealer may order the necessary parts for the repair. Instructions for making this correction have been sent to your dealer and parts are available. The labor time necessary to perform this service correction is approximately 25 minutes. Please ask your dealer if you wish to know hcw much additional time will be needed to schedule and process your vehicle. Your Chevrolet dealer is best equipped to obtain parts and provide service to ensure that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed service date, and they do not remedy this condition on that date or within five (5) days, we recommend you contact the Chevrolet Customer Assistance Center by calling 1-800-222-1020. After contacting your dealer and the Customer Assistance Center, if you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call 1-800-424-9393 (Washington D.C. residents use 366-0123). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Door 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 5623 Front Door Window Glass: Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box 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 add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 5624 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Technical Service Bulletins > Tools - Rear Compartment Lid Hinge Torque Rod Service Trunk / Liftgate Hinge: Technical Service Bulletins Tools - Rear Compartment Lid Hinge Torque Rod Service Number: 93-92-10 Section: 10 Date: JAN. 1993 Corporate Bulletin No.: 231076 ASE No.: B1 Subject: SERVICE TOOL FOR THE REAR COMPARTMENT LID HINGE TORQUE RODS Model and Year: 1982-92 CAVALIER 1988-93 CORSICA AND BERETTA SERVICE UPDATE APPLICATION: "J" Series: 1982 - 1992 "L" Series: 1988 - 1993 This is a service manual update to Section 10-8 regarding a service tool developed to assist in adjusting and/or replacing rear compartment lid hinge torque rods. Adjust: When adjusting the tension on torque rods, raise or lower either the right or left torque rod one adjusting notch at a time. It is important to keep the tension on both torque rods as close as possible. To increase the tension on the rear compartment lid hinge, move the end of the torque rod down a notch. To decrease the tension on the rear compartment lid hinge, move the end of the torque rod up a notch. CAUTION: To avoid eye and hand injury, always wear safety glasses and gloves when adjusting and/or replacing the rear compartment lid hinge torque rods. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Technical Service Bulletins > Tools - Rear Compartment Lid Hinge Torque Rod Service > Page 5630 Figure 1: 1. Prop rear compartment lid in full-open position to keep lid from falling in case torque rod(s) (1) is disengaged completely from retaining bracket (4). 2. Using tool J-39719 and a 1/2" drive socket extension, disengage end of torque rod(s) (1) from adjusting notches (3) and reposition rod(s) (1) as necessary. Remove or Disconnect: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Technical Service Bulletins > Tools - Rear Compartment Lid Hinge Torque Rod Service > Page 5631 1. Prop rear compartment lid in full-open position to keep lid from failing when torque rod(s) (1) is completely disengaged from retaining bracket (4). 2. Using tool J-39719 and a 1/2" drive socket extension, remove end of torque rod(s) (1) by rotating end of torque rod out of adjusting notches (3) and remove torque rod(s). Install or Connect: 1. Attach tool J-39719 to torque rod(s) (1) and hinge rear of torque rod on retaining bracket (4) as shown in Figure 1. 2. Insert end of torque rod(s) (1) to the appropriate adjusting notch (3). Use applicable labor operation time. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations > Except Wagon Trunk / Liftgate Solenoid: Locations Except Wagon Under Center Rear Of Luggage Compartment Lid Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations > Except Wagon > Page 5636 Trunk / Liftgate Solenoid: Locations Wagon Below RH Side Of Tailgate Window Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations Lower Center Portion Of Tailgate Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Body Squeeze Type Resistance Spot Welding/Equipment Frame: Technical Service Bulletins Body - Squeeze Type Resistance Spot Welding/Equipment INFORMATION Bulletin No.: 03-08-98-002B Date: June 30, 2010 Subject: Squeeze Type Resistance Spot Welding/Equipment Models: 2011 and Prior Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 03-08-98-002A (Section 08 - Body and Accessories). This bulletin provides guidelines for repair shops that wish to use squeeze type resistance spot welding (or simply, spot welding) as an alternative to MIG plug welding when performing collision repair procedures. The process of spot welding for attaching body panels and components has been around for many years and is similar to the production welding process used in assembly plants. Spot welding may be applicable in similar situations that are currently MIG plug welded. The following are some of the benefits of spot welding: - Less heat or burn damage - Less damage to corrosion protection - Drilling of holes not required - Replication of the production weld appearance Applicable components for this technology may be panels or components with flanges that are accessible with arms and tips supplied by the equipment manufacturer. Welds from this equipment should be applied on a one-for-one basis, next to the production welds. Here are some of the important factors in proper welding with this equipment. Important Proper use and safety training for each user of the equipment is a must. - Use equipment from companies that are able to produce welds that meet industry standards for size and strength. Equipment most likely to meet those standards at this time would be "inverter" technology and include the following suppliers (other suppliers may have comparable equipment): - Pro Spot (PR2000) - Elektron (M100) - Blackhawk (WEL700) - Car-O-Liner (CR500) For specific information about this and other equipment, call GM Dealer Equipment. - Ensure that the building power source is capable of meeting the equipment manufacturer's power requirement specifications. For example, fuse 60 amp, 208-230 V single or 3-phase, using supply wire of sufficient gauge to carry the current load. Consult with a qualified electrician for wiring assistance. - Prepare and perform sample welds for destructive testing made from similar materials. Perform this operation for each vehicle repaired and prior to actual repair. - Proper equipment maintenance - Proper weld tip alignment and maintenance - Ensure that metal flanges are clean and conform to each other A more complete description of these practices and standards can be found in the following publications: - SAE J-2667, Surface Vehicles Recommended Practice, http://www.sae.org - AWS D8.7-88, Recommended Practices Automotive Weld Quality - Resistance Spot Welding, http://www.aws.org/w/a/ - AWS D8.9-97, Recommended Practices for Test Methods for Evaluating the Resistance Spot Welding Behavior of Automotive Sheet Steels, http://www.aws.com Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Body Squeeze Type Resistance Spot Welding/Equipment > Page 5649 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 5655 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 5656 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 5657 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 5658 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Console - Park Brake Lever Brushes Loose Console: Technical Service Bulletins Console - Park Brake Lever Brushes Loose Number: 92-251-5 Section: 5 Date: AUGUST 1992 Corporate Bulletin No.: 238302 ASE No.: A5 Subject: CONSOLE PARK BRAKE LEVER BRUSH LOOSE Model and Year: 1991-92 CAVALIER Condition: Examination of returned parts on some Chevrolet Cavalier cars have revealed that replacement has been due to park brake brushes that become loose. Affected consoles can be repaired instead of replaced. Correction: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Console - Park Brake Lever Brushes Loose > Page 5663 Remove console assembly, following the appropriate 1991 and 1992 "J" Car Service Manual procedure in Section 8C. Apply adhesive P/N 12345632, or equivalent, as shown and hold in place for approximately one minute. Parts are currently available from GMSPO. Labor Operation Number C-2860 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling the SIR System Air Bag(s) Arming and Disarming: Service and Repair Disabling the SIR System The diagnostic energy reserve module (DERM) can maintain voltage to cause a system deployment for up to ten minutes after the ignition switch is turned off and the battery is disconnected. Servicing the SIR system during this period may result in accidental deployment and personal injury. 1. Ensure front wheels are pointed straight ahead. 2. Turn ignition switch to Lock position and remove SIR or AIRBAG fuse. 3. Remove lower left sound insulator. 4. Remove connector position assurance (CPA) lock and disconnect yellow two-way SIR harness connector at base of steering column. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling the SIR System > Page 5669 Air Bag(s) Arming and Disarming: Service and Repair Enabling the SIR System 1. Connect yellow two-way SIR harness connector and install CPA lock. 2. Install left sound insulator. 3. Install SIR fuse. 4. Turn ignition switch to Run position and ensure ``Inflatable Restraint'' lamp flashes 7-9 times and then remains off. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > Customer Interest for Drink Holders: > 937110 > Dec > 92 > I/P Cup Holder - Binding/Stuck Drink Holders: Customer Interest I/P Cup Holder - Binding/Stuck Number: 93-71-10 Section: 10 Date: DEC. 1992 Corporate Bulletin No.: 238301R ASE No.: B1 Subject: INSTRUMENT PANEL CUP HOLDER BINDING/STUCK Model and Year: 1991-93 CAPRICE, CAVALIER, CORSICA, BERETTA, PRIZM AND C/K TRUCKS (WITH BENCH SEATS) Condition: Some owners of 1991-93 "B/J/L/S" cars and C/K trucks (with bench seats) may comment on the operation of the Instrument Panel (I/P) cup holder as sticking or binding. Cause: Carbonated soft drinks or fruit juices spilled on the sliding surfaces of the tracks may inhibit free movement of the cup holder. Correction: Free operation may be restored as follows: 1. Remove I/P cup holder as outlined in appropriate service manual. 2. Wash thoroughly with luke-warm water and mild hand or dish soap and air dry. Harsh, chlorinated or soaps containing grit should not be used. 3. Reinstall cup holder. This is not to be considered a warranty expense item and cup holders should not be replaced for this condition. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drink Holders: > 937110 > Dec > 92 > I/P Cup Holder Binding/Stuck Drink Holders: All Technical Service Bulletins I/P Cup Holder - Binding/Stuck Number: 93-71-10 Section: 10 Date: DEC. 1992 Corporate Bulletin No.: 238301R ASE No.: B1 Subject: INSTRUMENT PANEL CUP HOLDER BINDING/STUCK Model and Year: 1991-93 CAPRICE, CAVALIER, CORSICA, BERETTA, PRIZM AND C/K TRUCKS (WITH BENCH SEATS) Condition: Some owners of 1991-93 "B/J/L/S" cars and C/K trucks (with bench seats) may comment on the operation of the Instrument Panel (I/P) cup holder as sticking or binding. Cause: Carbonated soft drinks or fruit juices spilled on the sliding surfaces of the tracks may inhibit free movement of the cup holder. Correction: Free operation may be restored as follows: 1. Remove I/P cup holder as outlined in appropriate service manual. 2. Wash thoroughly with luke-warm water and mild hand or dish soap and air dry. Harsh, chlorinated or soaps containing grit should not be used. 3. Reinstall cup holder. This is not to be considered a warranty expense item and cup holders should not be replaced for this condition. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Door Lock Cylinder: > 9313310 > Mar > 93 > Door Locks - Binding or Sticking or Key Hard to Insert Door Lock Cylinder: Customer Interest Door Locks - Binding or Sticking or Key Hard to Insert Number: 93-133-10 Section: 10 Date: MARCH 1993 Corporate Bulletin No.: 1341070R ASE No.: B1 Subject: DOOR LOCK CYLINDERS (RECOMMENDED LUBRICATION) Model and Year: ALL 1993 AND PREVIOUS MODEL CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN 92-41-10, DATED NOV. 1991. THE 1993 MODEL YEAR HAS BEEN ADDED AS WELL AS A NOTE. PLEASE DISCARD ALL COPIES OF 92-41-10. Customer comments of binding/sticking door lock cylinders, or keys that are hard to insert or extract may be corrected in many cases by applying the proper lubrication. The recommended materials for lubricating these components are (in order of preference): - GM # 12345120 Multi purpose lubricant (9 oz. spray) or # 12345121 (12 oz.). - 5 W 30 Motor Oil - GM # 1052276 or 1052277 spray type Silicone (4.5 oz. or 12 oz. cans). Penetrating oil type lubricants (such as GM # 1052949 or 1052950, WD-40 lubricants) ARE NOT RECOMMENDED because they wash out the original lubrication and eventually evaporate, leaving little or no lubricating material. However, if these type materials are used to "unfreeze" or loosen lock cylinder components, refer to steps 2 through 4 listed below for the proper methods of lubricating. NOTE: DO NOT REPLACE THE DOOR LOCK CYLINDERS UNTIL AFTER THE LUBRICATING MATERIALS HAVE BEEN USED AND THE CYLINDER REMAINS FROZEN/BOUND. If door lock cylinders require replacement for any reason, apply a coating of GM # 12345120 Multi purpose Lubricant to the inside of the lock case and the cylinder keyway prior to assembling and installing the cylinder. Parts are currently available from GMSPO. Frozen cylinders due to cold weather may be repaired using the following procedure: 1. Apply heat to the cylinder area with a heat gun while being careful not to damage the painted surfaces. 2. Hold the shutter door open with a paper clip (or similar item) and force air into the cylinder using compressed air and a blow gun attachment. 3. While holding the shutter door open, inject a small amount of lubricant (see above recommendations) into the cylinder. 4. Work the key into the cylinder several times and wipe any excess lubrication residue from the key. Use applicable Labor Time Number and Time allowance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 9313310 > Mar > 93 > Door Locks Binding or Sticking or Key Hard to Insert Door Lock Cylinder: All Technical Service Bulletins Door Locks - Binding or Sticking or Key Hard to Insert Number: 93-133-10 Section: 10 Date: MARCH 1993 Corporate Bulletin No.: 1341070R ASE No.: B1 Subject: DOOR LOCK CYLINDERS (RECOMMENDED LUBRICATION) Model and Year: ALL 1993 AND PREVIOUS MODEL CARS AND TRUCKS THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN 92-41-10, DATED NOV. 1991. THE 1993 MODEL YEAR HAS BEEN ADDED AS WELL AS A NOTE. PLEASE DISCARD ALL COPIES OF 92-41-10. Customer comments of binding/sticking door lock cylinders, or keys that are hard to insert or extract may be corrected in many cases by applying the proper lubrication. The recommended materials for lubricating these components are (in order of preference): - GM # 12345120 Multi purpose lubricant (9 oz. spray) or # 12345121 (12 oz.). - 5 W 30 Motor Oil - GM # 1052276 or 1052277 spray type Silicone (4.5 oz. or 12 oz. cans). Penetrating oil type lubricants (such as GM # 1052949 or 1052950, WD-40 lubricants) ARE NOT RECOMMENDED because they wash out the original lubrication and eventually evaporate, leaving little or no lubricating material. However, if these type materials are used to "unfreeze" or loosen lock cylinder components, refer to steps 2 through 4 listed below for the proper methods of lubricating. NOTE: DO NOT REPLACE THE DOOR LOCK CYLINDERS UNTIL AFTER THE LUBRICATING MATERIALS HAVE BEEN USED AND THE CYLINDER REMAINS FROZEN/BOUND. If door lock cylinders require replacement for any reason, apply a coating of GM # 12345120 Multi purpose Lubricant to the inside of the lock case and the cylinder keyway prior to assembling and installing the cylinder. Parts are currently available from GMSPO. Frozen cylinders due to cold weather may be repaired using the following procedure: 1. Apply heat to the cylinder area with a heat gun while being careful not to damage the painted surfaces. 2. Hold the shutter door open with a paper clip (or similar item) and force air into the cylinder using compressed air and a blow gun attachment. 3. While holding the shutter door open, inject a small amount of lubricant (see above recommendations) into the cylinder. 4. Work the key into the cylinder several times and wipe any excess lubrication residue from the key. Use applicable Labor Time Number and Time allowance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 5702 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 5703 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 5704 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Tools - Keyless Entry Transmitter Tester Keyless Entry Transmitter: Technical Service Bulletins Tools - Keyless Entry Transmitter Tester File In Section: 9 - Accessories Bulletin No.: 83-90-12 Date: August, 1998 INFORMATION Subject: Essential Tool J 43241 Remote Keyless Entry and Passive Keyless Entry Transmitter Tester Models: 1990-99 Passenger Cars and Trucks with Remote Keyless Entry or Passive Keyless Entry Systems A new essential tool, J 43241 Remote Keyless Entry Transmitter Tester, has been sent to all GM Dealers. This tester can be used on all RKE and PKE systems, on past as well as current models. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Tools - Keyless Entry Transmitter Tester > Page 5710 Important: Before using the tester and the diagnostic chart, the following two steps must be performed. 1. Verify that the keyless entry transmitter is the correct model for the vehicle remote system. An incorrect model transmitter may pass this test, but may not activate the vehicle remote system. The correct transmitter can usually be identified by part number. 2. Ensure that the transmitter is synchronized with the vehicle (if applicable). Refer to Transmitter Synchronization in the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations Power Door Lock Actuator: Locations In Upper Front Of Respective Door Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 331708 > Nov > 93 > Paint - Clearcoat Degradation, Chalking and Whitening Paint: Customer Interest Paint - Clearcoat Degradation, Chalking and Whitening Group Ref.: Body Bulletin No.: 331708 Date: November, 1993 SUBJECT: CLEARCOAT DEGRADATION - CHALKING AND WHITENING MODELS: PASSENGER CARS WITH BASECOAT/CLEARCOAT CONDITION: The vehicle exterior surface may show large chalky or white patches in the clearcoat, usually but not limited to the horizontal surfaces. Blacks, Dark Blues, Reds, may have potential for this condition. On rare occasions, other colors may be involved. CAUSE: The clearcoat (with sunlight and heat) may degrade and turn white or chalky. IDENTIFICATION: On a clean surface, at or above room temperature, firmly apply a 2" wide piece of masking tape to the chalky or white area of the clearcoat and pull upward quickly. The adhesive side of the tape WILL NOT HAVE THE PAINT COLOR ON IT. A light shine or reduced tackiness may be noticed on the tape adhesive surface, indicating clearcoat transfer to the tape. CORRECTION: Refinish all horizontal surfaces using the following procedure. - Remove the clearcoat layer from all horizontal surfaces and the top surfaces of fenders and quarter panels. NOTE: In some cases, it will be necessary to remove the clearcoat from the upper vertical surfaces of fenders, doors and quarters (approximately 3"), and the top areas directly above the front and rear wheelhouse openings. - Lightly sand any previously exposed base color to remove any chalky residue from the surface. - The vertical surfaces should be sanded and colorcoated to the next lower breakline (typically the body side moldings) for color uniformity of the repair. IMPORTANT: The following procedure covers clearcoat degradation only. It does not address any other paint condition. PROCEDURE: 1. Some vehicle components will be removed, while others will require masking. The list located at the end of this bulletin will establish the removal items. Items not found on the list and non repair areas are to be masked. 2. Prior to removing the paint finish, clean the area to be refinished with soap and water, followed by an appropriate wax and grease remover. 3. Mask the remaining moldings and hardware for protection during sanding. 4. Remove the clearcoat material from all horizontal surfaces (and tops of fenders and quarters) using a DA (dual action orbital sander) and # 120 grit sanding discs. Lightly sand any previously exposed base color to remove any chalky residue from the surface. NOTE: Chemical stripping is not recommended because of negative Impact to moldings, non-metal components, ELPO and environmental concerns. 5. Lightly sand the unaffected vertical panels to the next lower breakline, smooth and "featheredge" the surface to be refinished with # 240 or # 320 grit sandpaper for maximum adhesion. 6. Blow off the sanding dust and residue. 7. Remove masking tape and remask all necessary areas for priming. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 331708 > Nov > 93 > Paint - Clearcoat Degradation, Chalking and Whitening > Page 5729 8. Wipe and clean repair area with an appropriate wax and grease remover. 9. Wipe repair area with a tack rag. 10. Apply a coat of self etching or epoxy primer to the bare metal areas exposed during the sanding process. Follow manufacturer's instructions and recommended dry times. Typical materials would be: DuPont 615S/616S, BASF DE17/PR80/DA18, PPG DP40/DP401 or equivalent. V.O.C. materials would be: DuPont 615S/616S, BASF DE17/PR80/DA18, PPG DCP21/DCP212 or equivalent. 11. Apply two to three medium wet coats of primer surfacer to the entire repair area (including vertical surfaces) of the vehicle, following manufacturer's instructions for application and film build requirements. NOTE: A guide coat Is recommended to highlight high and low spots during the wet or dry sanding process. Typical materials would be: DuPont 1120S/1130S/1125S, BASF DP20/PR80/PH36, PPG K36/DT870/K201 or equivalent. V.O.C. materials would be: DuPont 275S, BASF HP400, PPG DCP21/DCP212 or equivalent. 12. After adequate drying time, wet sand with # 400 grit (or finer) or dry sand with # 320 grit (or finer) sand paper. 13. Repeat steps 6 through 9 and remask the vehicle. 14. Apply a medium coat of primer sealer to the entire repair area. Typical materials would be: DuPont 2610S/2605S, BASF DP21/DH60/PR80, PPG DP40/DP401 or equivalent. V.O.C. materials would be: DuPont 210S, PPG DPW1834 or equivalent. 15. Apply 2 to 3 medium wet coats of basecoat (or until primer is hidden). Follow manufacturer's instructions and recommended dry times. 16. Apply clearcoat. Follow manufacturer's instructions and recommended dry times. 17. After sufficient force dry or air dry time, remove masking. 18. Spot finesse/polish as required. 19. Reinstall previously removed hardware and moldings. HARDWARE ITEM REMOVAL Vehicles have many different hardware options and treatments, but the following list of items can be used as guidelines for item removal. ^ Windshield moldings (non-modular type windows) ^ Back window moldings (non-modular type windows) ^ Side view mirrors (outer panel mounted) ^ Ft. door belt seal strips (doors without window frames) ^ Name plates on fenders, doors, quarters, fascias and deck lids ^ Antenna base (power or fixed mast types) ^ Wiper arms (on vehicles with cowl grilles) ^ Cowl vent grille ^ Fender marker lamps ^ Tail lamps ^ Rocker aero molding emblems Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 331708 > Nov > 93 > Paint - Clearcoat Degradation, Chalking and Whitening > Page 5730 ^ Roof weld seam moldings ^ Auxiliary weatherstrips ^ Deck lid lock cyl. cover ^ Wheel opening moldings ^ Roof drip scalp moldings ^ Door edge guards* ^ Spoilers* ^ Luggage racks* ^ Hood grills/ornaments* ^ Decals* ^ Stripes* ^ Body side moldings if mechanically retained. If adhesive retained, mask molding. NOTE: Only items marked with an asterisk are "add" conditions to the Major Operation being performed. Removal time for the other Items listed is included in the allowance. LABOR OPERATION: A6110 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 331708 > Nov > 93 > Paint - Clearcoat Degradation, Chalking and Whitening > Page 5731 TIME ALLOWANCE: See Chart That Follows (**) NOTE: The time allowances provided on the chart includes the hardware removal and installation (as indicated by the list guidelines), the masking and unmasking of the vehicle, clearcoat removal (as indicated by the guidelines), the refinish (and colorcoat when required), mix time for primer/paint and clearcoat, finesse/polish where required, washing and preparing the vehicle for delivery. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 72-05-11 > Dec > 97 > Warranty - Rail Dust Removal & Chemical Spotting Labor Paint: All Technical Service Bulletins Warranty - Rail Dust Removal & Chemical Spotting Labor File In Section: Warranty Administration Bulletin No.: 72-05-11 Date: December, 1997 WARRANTY ADMINISTRATION Subject: Clarification of Rail Dust Removal (A5575-A5580) and Chemical Spotting (A5541-A5544) Labor Operations Models: All Past and Future Passenger Cars and Light Duty Trucks The purpose of this Warranty Administration Bulletin is to clarify the usage, limits and guidelines for the proper use of the above subject labor operations. The above subject labor operations were introduced to correct paint imperfections caused by fallout that occurred either during shipment to the dealer or within the first 12 months or 12,000 miles (20,000 kms) of vehicle ownership. GM vehicle owners are informed that although no defect in the factory applied paint causes this, GM will repair, at no charge to the owner, the surfaces of new vehicles damaged by fallout condition within 12 months or 12,000 miles (20,000 kms) whichever occurs first. Effective with repair orders dated on or after December 1, 1997, labor operations A5575-A5580 Rail Dust Removal and A5541 through A5544 Chemical Spotting will be limited to within the first 12 months or 12,000 miles of the Base Vehicle Warranty (20,000 kms) whichever occurs first. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 331708 > Nov > 93 > Paint - Clearcoat Degradation, Chalking and Whitening Paint: All Technical Service Bulletins Paint - Clearcoat Degradation, Chalking and Whitening Group Ref.: Body Bulletin No.: 331708 Date: November, 1993 SUBJECT: CLEARCOAT DEGRADATION - CHALKING AND WHITENING MODELS: PASSENGER CARS WITH BASECOAT/CLEARCOAT CONDITION: The vehicle exterior surface may show large chalky or white patches in the clearcoat, usually but not limited to the horizontal surfaces. Blacks, Dark Blues, Reds, may have potential for this condition. On rare occasions, other colors may be involved. CAUSE: The clearcoat (with sunlight and heat) may degrade and turn white or chalky. IDENTIFICATION: On a clean surface, at or above room temperature, firmly apply a 2" wide piece of masking tape to the chalky or white area of the clearcoat and pull upward quickly. The adhesive side of the tape WILL NOT HAVE THE PAINT COLOR ON IT. A light shine or reduced tackiness may be noticed on the tape adhesive surface, indicating clearcoat transfer to the tape. CORRECTION: Refinish all horizontal surfaces using the following procedure. - Remove the clearcoat layer from all horizontal surfaces and the top surfaces of fenders and quarter panels. NOTE: In some cases, it will be necessary to remove the clearcoat from the upper vertical surfaces of fenders, doors and quarters (approximately 3"), and the top areas directly above the front and rear wheelhouse openings. - Lightly sand any previously exposed base color to remove any chalky residue from the surface. - The vertical surfaces should be sanded and colorcoated to the next lower breakline (typically the body side moldings) for color uniformity of the repair. IMPORTANT: The following procedure covers clearcoat degradation only. It does not address any other paint condition. PROCEDURE: 1. Some vehicle components will be removed, while others will require masking. The list located at the end of this bulletin will establish the removal items. Items not found on the list and non repair areas are to be masked. 2. Prior to removing the paint finish, clean the area to be refinished with soap and water, followed by an appropriate wax and grease remover. 3. Mask the remaining moldings and hardware for protection during sanding. 4. Remove the clearcoat material from all horizontal surfaces (and tops of fenders and quarters) using a DA (dual action orbital sander) and # 120 grit sanding discs. Lightly sand any previously exposed base color to remove any chalky residue from the surface. NOTE: Chemical stripping is not recommended because of negative Impact to moldings, non-metal components, ELPO and environmental concerns. 5. Lightly sand the unaffected vertical panels to the next lower breakline, smooth and "featheredge" the surface to be refinished with # 240 or # 320 grit sandpaper for maximum adhesion. 6. Blow off the sanding dust and residue. 7. Remove masking tape and remask all necessary areas for priming. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 331708 > Nov > 93 > Paint - Clearcoat Degradation, Chalking and Whitening > Page 5745 8. Wipe and clean repair area with an appropriate wax and grease remover. 9. Wipe repair area with a tack rag. 10. Apply a coat of self etching or epoxy primer to the bare metal areas exposed during the sanding process. Follow manufacturer's instructions and recommended dry times. Typical materials would be: DuPont 615S/616S, BASF DE17/PR80/DA18, PPG DP40/DP401 or equivalent. V.O.C. materials would be: DuPont 615S/616S, BASF DE17/PR80/DA18, PPG DCP21/DCP212 or equivalent. 11. Apply two to three medium wet coats of primer surfacer to the entire repair area (including vertical surfaces) of the vehicle, following manufacturer's instructions for application and film build requirements. NOTE: A guide coat Is recommended to highlight high and low spots during the wet or dry sanding process. Typical materials would be: DuPont 1120S/1130S/1125S, BASF DP20/PR80/PH36, PPG K36/DT870/K201 or equivalent. V.O.C. materials would be: DuPont 275S, BASF HP400, PPG DCP21/DCP212 or equivalent. 12. After adequate drying time, wet sand with # 400 grit (or finer) or dry sand with # 320 grit (or finer) sand paper. 13. Repeat steps 6 through 9 and remask the vehicle. 14. Apply a medium coat of primer sealer to the entire repair area. Typical materials would be: DuPont 2610S/2605S, BASF DP21/DH60/PR80, PPG DP40/DP401 or equivalent. V.O.C. materials would be: DuPont 210S, PPG DPW1834 or equivalent. 15. Apply 2 to 3 medium wet coats of basecoat (or until primer is hidden). Follow manufacturer's instructions and recommended dry times. 16. Apply clearcoat. Follow manufacturer's instructions and recommended dry times. 17. After sufficient force dry or air dry time, remove masking. 18. Spot finesse/polish as required. 19. Reinstall previously removed hardware and moldings. HARDWARE ITEM REMOVAL Vehicles have many different hardware options and treatments, but the following list of items can be used as guidelines for item removal. ^ Windshield moldings (non-modular type windows) ^ Back window moldings (non-modular type windows) ^ Side view mirrors (outer panel mounted) ^ Ft. door belt seal strips (doors without window frames) ^ Name plates on fenders, doors, quarters, fascias and deck lids ^ Antenna base (power or fixed mast types) ^ Wiper arms (on vehicles with cowl grilles) ^ Cowl vent grille ^ Fender marker lamps ^ Tail lamps ^ Rocker aero molding emblems Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 331708 > Nov > 93 > Paint - Clearcoat Degradation, Chalking and Whitening > Page 5746 ^ Roof weld seam moldings ^ Auxiliary weatherstrips ^ Deck lid lock cyl. cover ^ Wheel opening moldings ^ Roof drip scalp moldings ^ Door edge guards* ^ Spoilers* ^ Luggage racks* ^ Hood grills/ornaments* ^ Decals* ^ Stripes* ^ Body side moldings if mechanically retained. If adhesive retained, mask molding. NOTE: Only items marked with an asterisk are "add" conditions to the Major Operation being performed. Removal time for the other Items listed is included in the allowance. LABOR OPERATION: A6110 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 331708 > Nov > 93 > Paint - Clearcoat Degradation, Chalking and Whitening > Page 5747 TIME ALLOWANCE: See Chart That Follows (**) NOTE: The time allowances provided on the chart includes the hardware removal and installation (as indicated by the list guidelines), the masking and unmasking of the vehicle, clearcoat removal (as indicated by the guidelines), the refinish (and colorcoat when required), mix time for primer/paint and clearcoat, finesse/polish where required, washing and preparing the vehicle for delivery. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 923310 > Nov > 91 > Paint - Acid Rain Damage to Base Coat/Clear Coat Paint: All Technical Service Bulletins Paint - Acid Rain Damage to Base Coat/Clear Coat Number: 92-33-10 Section: 10 Date: NOV. 1991 Corporate Bulletin No.: 131060 ASE No.: B2 Subject: INDUSTRIAL FALLOUT/RAIL DUST DAMAGE TO BASE COAT/CLEAR COAT Model and Year: 1983-92 ALL PASSENGER CARS AND TRUCKS Application: 1992 (and previous) models with Base Coat/Clear Coat Paint The following information regards the use of finesse type repairs to environmental (industrial fallout) and rail dust damage of base coat/clear coat paint finishes. Since the severity of the condition varies from area to area, PROPER DIAGNOSIS of the damage extent is CRITICAL TO THE SUCCESS OF REPAIRS. Diagnosis should be performed under high intensity fluorescent lighting, on horizontal surfaces (hood, roof, decklid) after they have been properly cleaned. INDUSTRIAL FALLOUT (ACID RAIN) There are three basic types of acid rain damage: Surface level contamination, - may be repaired by simply washing the vehicle, cleaning the surface with a wax and grease remover, neutralizing acidic residue and finesse polishing. - Clearcoat etching, - slight etching still noticeable after the above washing and finesse polishing procedure. - Basecoat etching, - severe etching beyond the clearcoat into the basecoat. PROCEDURES FOR SURFACE LEVEL CONTAMINATION REPAIRS 1. Wash the vehicle with standard car detergent and water and dry thoroughly. 2. Clean the affected area with a wax and grease remover. 3. Neutralize any left over acidic residue by cleaning the damaged areas with a mixture of baking soda and water (one tablespoon per quart of water), rinse THOROUGHLY and dry the panels completely. 4. Apply a finesse type polish with a foam pad. CLEAN AND INSPECT THE SURFACE A. If the damage has been repaired, remove any swirl marks with a dual action orbital polisher and foam pad. B. If some damage remains, proceed to step 5. SLIGHT CLEARCOAT DAMAGE - WET SANDING, FINESSE POLISHING 5. Select a small test area on a damaged panel. 6. Wet sand the damaged area with an American Grade ultra fine sandpaper of 1,500 to 2,000 grit and a rubber sponge sanding block. During the wet sand process; a. Use ample amounts of water b. Go slow to prevent removing too much clearcoat. Note: Be sure to use American Sandpaper. European Sandpaper has a "P" before the grit number and European grits do not align with American grits the majority of the time. 7. Remove the excess water with a rubber squeegee and inspect the area. A. If this has repaired the damage, continue the sanding procedure on the entire panel, apply a finesse type polish with a foam pad and remove any swirl marks with a dual action orbital polisher and foam pad. B. If (during the repair) it is suspected or observed that; - etching has penetrated into the base coat OR - too much clearcoat has been removed during sanding OR - base color is transferred to pad during polishing, Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 923310 > Nov > 91 > Paint - Acid Rain Damage to Base Coat/Clear Coat > Page 5752 The AFFECTED AREAS MAY REQUIRE RECLEARCOATING/COLORCOATING OR REFINISHING. 8. In any case, once the proper repairs have been made, the final step in the repair process involves polishing the vehicle. A WORD ABOUT CLEARCOAT THICKNESS The clearcoat on the vehicle is typically 1.5 to 2.0 mils thick (one mil equals .001" or 1/1,000 of an inch). At least one mil thickness is required to provide lasting protection to the vehicle basecoat. PAINT GAGES The best way to accurately measure how much clearcoat has been removed is to use a paint gage before, during and after the sanding process. Paint gages measure the total thickness of the finish and when used, can determine how much clearcoat has been removed during the repair process. Paint gages range from magnetic pull types to sophisticated electronic types, are available from a variety of sources, and can cost from $30 to $1800. The older magnetic type gages, at best, a +/- 5% accuracy range and are not sensitive enough to detect removal of .5 mil clearcoat. The newer type magnetic gages have improved accuracy ranges. Most gages are confined to checking either a ferrous metal (steel) or non-ferrous metal (aluminum) panels. At this time, there are no viable gages for reading film thickness on non-metallic panels. A more sophisticated gage is the digital Elcometer 300 fn Paint Thickness gage (or equivalent). It has an ability to read film thickness on both ferrous and non-ferrous metal panels. This instrument has an accuracy range of +/- 1% and has thickness standards included for recalibration. Approximate cost = $1750. An alternative (for use on steel panels only) would be the digital Elcometer 246 model, or equivalent. This gage has a +/- 3% accuracy range and include thickness standards for recalibration. Approximate cost - $575. REPAIRING RAIL DUST DAMAGE Rail dust damage comes from the tiny iron particles produced from the friction between the train wheels and the track. It can also be deposited on vehicles if stored near any operation producing iron dust (steel ore yards, etc.). This dust can either lay on top of, or embed into the paint surface. It is usually diagnosed as; bumps in the paint surface OR - rust colored spots in the paint. PROCEDURE: 1. Wash the vehicle with soap and water, dry it and clean the affected area with wax and grease remover. 2. Keeping the vehicle in a cool or shaded area, rinse the surface with cold water. 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 IT, USE THE NECESSARY SAFETY EQUIPMENT, INCLUDING GLOVES AND GOGGLES. FOLLOW THE MANUFACTURER'S DIRECTIONS CLOSELY BECAUSE IT MAY REQUIRE SPECIAL HANDLING AND DISPOSAL. 3. Soak several terry cloth towels in a container of rail dust remover solution and, after the damaged areas have been rinsed with cold water, lay the wet towels on the damaged areas. 4. Allow the towels to remain in place for 20 minutes, keeping them moist by spraying with water and not allowing to dry on the surface of the vehicle. 5. After 20 minutes of applying the towels, remove them and rinse the area thoroughly with cold water. Inspect the affected area to ensure the dust has been removed. Use both touch (feeling for bumpy surface) and sight (magnifying glass for close inspection). 6. If upon inspection some particles are still present, the process of applying the towels can be repeated 3 times. 7. Select a test area and hand wet sand with American ultra fine 1,500 grit to 2,000 grit sandpaper to repair damage (surface pitting from dust). a. Use ample amounts of water. b. Go slow to prevent removing too much clearcoat. NOTICE: USE A PAINT GAGE TO DETERMINE THE AMOUNT OF CLEARCOAT REMOVED. IF TOO MUCH HAS BEEN REMOVED, ADDITIONAL CLEARCOAT WILL HAVE TO BE APPLIED. IF RAIL DUST HAS PENETRATED INTO THE BASECOAT, THE PANEL REQUIRES REFINISHING. MAKE SURE ALL RAIL DUST HAS BEEN REMOVED PRIOR TO REFINISHING OR THE RUST SPOTS WILL RETURN, CAUSING CUSTOMER COMEBACKS. 8. If the damage has been repaired, complete the repair to the entire panel. 9. Once the damage has been repaired, the final step in the repair process involves polishing the vehicle. PREVENTING INDUSTRIAL FALLOUT DAMAGE Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 923310 > Nov > 91 > Paint - Acid Rain Damage to Base Coat/Clear Coat > Page 5753 Customers should be urged to wash and dry their vehicles frequently and garage them, or at least cover them with a quality car cover when not in use. Vehicles in dealer inventories should be kept clean and dry. A vehicle that sits unattended, especially after the sun has dried any water on the body surface, is a target for acid rain damage. MATERIALS DESCRIBED IN THIS BULLETIN* WAX AND GREASE REMOVER - USE BELOW OR EQUIVALENT Dupont # 3919S, PPG # DX440, BASF # 900, SIKKENS # 6041 FINESSE POLISHES - USE BELOW OR EQUIVALENT Dupont # 1500S, 3000S; BASF # 563-808, 560-1502; PPG # DRX10; 3M PERFECT-IT * USE V.O.C. EQUIVALENTS IN STATES WITH V.O.C. RESTRICTIONS RAIL DUST REMOVER - USE BELOW OR EQUIVALENT Industrial Fallout Remover # 5029 Zep Corporation Atlanta, GA. Telephone # 404-352-1680 Stain Away # HBY 0160 Hornby Chemical Milwaukee, WI. Telephone # 414-462-2833 If the rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. PAINT GAGES - USE BELOW OR EQUIVALENT Elcometer Inc. 1893 Rochester Ind. Drive Rochester Hills, MI. 48309 (800) 521-0635 or (313) 650-0500 Zelcro, Ltd./Zormco 8520 Garfield Rd. Cleveland, OH 44125 (216) 441-6102 Delfesko Corp. 410 Cedar St. Ogdensburg, NY 13669 (800) 267-0607 or (613) 925-5987 Pro Motorcar Products Inc. 22025 US-19 North Clearwater, FL 34625 (800) 323-1090 (813) 726-9225 "We believe these sources and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources." Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9133410 > May > 91 > Paint - High Volume Low Pressure Paint Application Paint: All Technical Service Bulletins Paint - High Volume Low Pressure Paint Application Number: 91-334-10 Section: 10 Date: MAY 1991 Corporate Bulletin No.: 161701R Subject: HVLP-HIGH VOLUME LOW PRESSURE PAINT APPLICATION Model and Year: 1982-91 ALL PASSENGER CARS AND TRUCKS VOC stands for Volatile Organic Compounds. Most solvents used in automotive refinishing paints are considered volatile organic compounds. Volatile organic compounds react chemically with sunlight and make a variety of pollutants generally referred to as "Photochemical Smog." VOC regulations seek to reduce the amount of VOC getting into the air and thereby limit pollution. One way to reduce the amount of volatile organic compounds being emitted into the air is to increase the transfer efficiency rate of the paint material being transferred between the spray gun and the surface being painted. Different states throughout the country, such as California, New York, New Jersey, etc., are in the process of writing VOC emission regulations. As an example, the South Coast Air Quality Management District (SCAOMD) in Southern California has a Rule 1151 for automotive refinishing that stipulates that coating applications must be done with either electrostatic application, high-volume, low-pressure (HVLP) spray or "such other coating application methods that are demonstrated to the executive officer to be capable of achieving at least 65 percent transfer efficiency." HVLP spray is defined as "to spray a coating by means of a gun that operates between 0.1 and 10.0 psi air pressure." What is the difference between the high pressure conventional spray guns now in use and the HVLP spray guns being stipulated in VOC regulations? In the conventional spray gun high pressure air leaves the air cap and rapidly expands. As this air expands, the paint from the fluid tip is blasted apart, sending small paint droplets in all directions at a high velocity. This explosion of paint causes much of the paint to pass or bounce off the surface being painted. Transfer efficiency on conventional spray guns is usually between 20 percent and 50 percent efficiency. HVLP stands for (H)igh (V)olume (L)ow (P)ressure. HVLP spray guns utilize lower spray pressures upon atomization. The relatively low air pressure causes a much "softer" explosion. The resultant paint droplets are larger and slower. The large volume of air from the air caps can now better control the flight of the droplets. The paint spray tends to move in one direction. Bounce back and paint passing by the substrate are reduced, resulting in increased transfer efficiency. Transfer efficiency of HVLP guns is usually between 65 percent to 90 percent efficient. The amount of savings and transfer efficiency varies with the skill of the painter, gun adjustment, the air pressures, the size of the object being painted, and the viscosity of the paint. Basically, there are three types of HVLP spray equipment available; turbine units, air conversion units, and spray guns with the air conversion units inside the gun. The turbine unit is normally a portable or wall-mounted unit that generates a high volume of air at between 3 to 7 psi. Due to friction, the turbine generates heat. The amount of heat generated and the temperature of the air depend on the size of the turbine and length of hose. A large size diameter air hose is used between the turbine and the HVLP spray gun. Air conversion units are normally portable or wall-mounted units that use high pressure air from an air compressor and then convert it to a high volume of air at a lower pressure set on a regulator. Most air regulators on these units do not exceed 10 psi. A large size diameter air hose is used between the air conversion unit and the HVLP spray gun. These units do not generate any heat, but can be purchased with a heat source. HVLP spray guns with the air conversion units inside the gun use high pressure air from an air compressor and then convert it to a high volume of air at a preset pressure normally dependent on incoming air line pressure. The spray guns cannot exceed 10 psi no matter how high the incoming air line pressure is. There is no large diameter air hoses or heat to contend with. HVLP equipment that can maintain precise control and maintain close to 10 psi air cap pressure will provide better atomization of materials, especially low VOC paints. A GM training course on HVLP Paint Application is currently available (Course # 22001.42). Please refer to the GM monthly training schedule for more information. MANUFACTURERS of HVLP SPRAY EQUIPMENT Accuspray System Binks Bessam-Aire Binks Manufacturing Co. 26881 Cannon Road 9201 West Belmont Ave. P.O. Box 46478 Franklin Park, IL 60131 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9133410 > May > 91 > Paint - High Volume Low Pressure Paint Application > Page 5758 Cleveland, OH 44146-0478 708-671-3000 216-439-1200 Can-Am Croix Can-Am Engineered Croix Air Products Products. Inc. 520 Airport Rd./Flemingfield 30850 Industrial Rd. So. St Paul, MN 55074 Livinoia, MI 48150 612-455-1213 313-427-2020 DevilBiss Graco Inc. The Devilbiss Co. P.O. Box 1441 320 Phillips Ave. Minneapolis, MN 55440-1441 P.O. Box 913 1-800-367-4023 Toledo, OH 43962 419-470-2169 Lex-Air Turbine Spray Mattson Lex-Air South 230 West Coleman 5874 Buford Hwy. P.O. Box 132 Doraville, GA 30340 Rice Lake, WI 54868 404-454-8417 715-234-1617 Sata Sharpe Mfg. Sata Spray Equipment 1224 Wall St. P.O. Box 46 Hwy. 16&63 N. P.O. Box 15042 Spring Valley, MN 55975 Los Angeles, CA 90015-0042 507-346-7102 213-749-4368 Xcel Spray Smith Eastern Corporation 5020 Sunnyside Ave. #207 Beltsville, MD 20705 301-937-4548 We believe the sources listed in this bulletin and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from this firm or for any such item which may be available from other sources. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9128210 > Apr > 91 > Paint - Importance of Checking Clear Coat Thickness Paint: All Technical Service Bulletins Paint - Importance of Checking Clear Coat Thickness Number: 91-282-10 Section: 10 Date: APRIL 1991 Corporate Bulletin No.: 111701R Subject: IMPORTANCE OF CHECKING CLEAR COAT THICKNESS BEFORE AND AFTER PAINT FINESSE OPERATIONS Model and Year: 1984-91 ALL PASSENGER CARS 1984-91 M VAN AND C/K TRUCKS 1987-9.1 R/V TRUCKS 1990-91 L AND U VAN THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-255-10, DATED MARCH 1991. THE SUPPLIER ADDRESS HAS BEEN CORRECTED. ALL COPIES OF 91-255-10 SHOULD BE DISCARDED. Finesse procedures may result in a lowering of the clear coat protective film below the level necessary to provide minimum durability and performance requirements. As time progresses, a severe "whitening" or degradation of the clear coat may occur when the clear coat is removed below the minimum GM specification. A paint thickness gage should be used to determine how much of the clear coat has been removed by the polishing or compounding process. Readings of the paint film build should be taken prior to the finesse operation. As the finesse operation progresses, additional readings should be taken to determine the impact on the total film build. If the gage indicates the total thickness has been reduced by .5 mils, it will be necessary to re-spray clear on the repair area to restore the needed ultraviolet protection. If the base coat is disturbed, a complete repainting process is required. There are many types of paint thickness gages available to the refinisher in today's market. The older magnetic-type gages, the best of which have a +/- 5% accuracy range, are not sensitive enough to detect a .5 mil removal of clear coat. Most gages are confined to checking either a ferrous substrate (steel), or a non-ferrous metal substrate. At this time, there is no viable gage for reading film thicknesses on a non-metallic substrate (such as plastic or rubber). The digital Elcometer 300 fn paint thickness gage, or equivalent, has the ability to read film thicknesses on both ferrous and non-ferrous metal substrates. With thickness standards included for recalibration purposes, this instrument is capable of reading film thicknesses within an accuracy range of +/- 1%. The approximate cost of the unit is $1750. As an alternative unit for the refinisher who deals only with traditional steel components. The digital Elcometer 246 model, or equivalent may be used. The gage demonstrates a +/- 3% accuracy range and comes with thickness standards for recalibration. The approximate cost of this unit is $575. Other digital paint thickness gages are available from the suppliers listed below which demonstrate the same accuracy levels as the recommended Elcometer models: Elcometer, Inc. Defelsko Corp. Zelcro, Ltd./Zormco 1893 Rochesterlnd. Drive 410 Cedar Street 8520 Garfield Road Rochester Hills, MI 48309 Ogdensburg, NY 13669 Cleveland, OH 44125 (800) 521-0635 or (800) 267-0607 or (216) 441-6102 (313) 650-0500 (613) 925-5987 We believe these sources, their equipment, and materials to be reliable. There may be additional manufacturers of such materials and equipment. General Motors does not endorse, indicate any preference for, or assume responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 915110 > Aug > 90 > Interior Body - Nonmetallic Paint Usage Paint: All Technical Service Bulletins Interior Body - Nonmetallic Paint Usage Number: 91-51-10 Section: 10 Date: August 1990 Corp. Bulletin No.: 071702 Subject: USAGE ON NONMETALLIC PAINT ON UNDERHOOD/INTERIOR TRUNK Model and Year: 1990 CELEBRITY, CAVALIER 1991 CAVALIER TO: ALL CHEVROLET DEALERS 1990 AW35 assembled in Ste. Therese. 1990-91 J assembled in Lordstown. The purpose of this bulletin is to advise the usage of nonmetallic paint in production on interior body areas assembled in Ste. Therese and Lordstown. These areas are painted using color-matched primer without basecoat/clearcoat. This produces a non-metallic color that closely coordinates to the topcoat color but has a lower gloss specification than the exterior topcoat. There will not be an exact match to metallic colors of exterior basecoat/clearcoat. If repairs of the primed areas are required, use basecoat/clearcoat enamel to match the exterior color. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9133510 > May > 91 > Seat (Passenger) - Will Not Lock Into Position Seat Track: All Technical Service Bulletins Seat (Passenger) - Will Not Lock Into Position Number: 91-335-10 Section: 10 Date: MAY 1991 Corporate Bulletin No.: 131025 Subject: PASSENGER SEAT WILL NOT LOCK INTO POSITION Model and Year: 1989-91 CAVALIER COUPE Models Affected: 1989 through early 1991 J Coupe, Models, except Cavalier Models with Value Leader Package. Condition: The standard passenger seat EZ Entry seat adjuster for 1989-1991 J coupe models may exhibit a no-lock condition when repositioning the seat assembly forward or backward. Cause: The latch return spring on the outer track of the seat adjuster may break when adjusting the seat assembly forward or backward. Once the spring is broken, the latch on the outer track cannot return to the lock position. Correction: Replace passenger seat outer latch return spring as follows: Remove or Disconnect: 1. Seat adjuster trim covers. 2. Seat adjuster-to-floor pan attaching nuts, then remove seat assembly from vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9133510 > May > 91 > Seat (Passenger) - Will Not Lock Into Position > Page 5772 3. Outer latch return spring from latch and track (Figure 1). Install or Connect: 1. Outer latch return spring, P/N 12510770 to latch and track (Figure 1). 2. Seat assembly into vehicle and install seat adjuster-to-floor pan attaching nuts. Tighten nuts to 29 N-m. (21 lbs.ft.). 3. Seat adjuster trim covers. Parts are currently available from GMSPO. Labor Operation Number: T1730 Labor Time: .3 Hour Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 5773 Paint: By Symptom Technical Service Bulletin # 331708 Date: 931101 Paint - Clearcoat Degradation, Chalking and Whitening Group Ref.: Body Bulletin No.: 331708 Date: November, 1993 SUBJECT: CLEARCOAT DEGRADATION - CHALKING AND WHITENING MODELS: PASSENGER CARS WITH BASECOAT/CLEARCOAT CONDITION: The vehicle exterior surface may show large chalky or white patches in the clearcoat, usually but not limited to the horizontal surfaces. Blacks, Dark Blues, Reds, may have potential for this condition. On rare occasions, other colors may be involved. CAUSE: The clearcoat (with sunlight and heat) may degrade and turn white or chalky. IDENTIFICATION: On a clean surface, at or above room temperature, firmly apply a 2" wide piece of masking tape to the chalky or white area of the clearcoat and pull upward quickly. The adhesive side of the tape WILL NOT HAVE THE PAINT COLOR ON IT. A light shine or reduced tackiness may be noticed on the tape adhesive surface, indicating clearcoat transfer to the tape. CORRECTION: Refinish all horizontal surfaces using the following procedure. - Remove the clearcoat layer from all horizontal surfaces and the top surfaces of fenders and quarter panels. NOTE: In some cases, it will be necessary to remove the clearcoat from the upper vertical surfaces of fenders, doors and quarters (approximately 3"), and the top areas directly above the front and rear wheelhouse openings. - Lightly sand any previously exposed base color to remove any chalky residue from the surface. - The vertical surfaces should be sanded and colorcoated to the next lower breakline (typically the body side moldings) for color uniformity of the repair. IMPORTANT: The following procedure covers clearcoat degradation only. It does not address any other paint condition. PROCEDURE: 1. Some vehicle components will be removed, while others will require masking. The list located at the end of this bulletin will establish the removal items. Items not found on the list and non repair areas are to be masked. 2. Prior to removing the paint finish, clean the area to be refinished with soap and water, followed by an appropriate wax and grease remover. 3. Mask the remaining moldings and hardware for protection during sanding. 4. Remove the clearcoat material from all horizontal surfaces (and tops of fenders and quarters) using a DA (dual action orbital sander) and # 120 grit sanding discs. Lightly sand any previously exposed base color to remove any chalky residue from the surface. NOTE: Chemical stripping is not recommended because of negative Impact to moldings, non-metal components, ELPO and environmental concerns. 5. Lightly sand the unaffected vertical panels to the next lower breakline, smooth and "featheredge" the surface to be refinished with # 240 or # 320 grit sandpaper for maximum adhesion. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 5774 6. Blow off the sanding dust and residue. 7. Remove masking tape and remask all necessary areas for priming. 8. Wipe and clean repair area with an appropriate wax and grease remover. 9. Wipe repair area with a tack rag. 10. Apply a coat of self etching or epoxy primer to the bare metal areas exposed during the sanding process. Follow manufacturer's instructions and recommended dry times. Typical materials would be: DuPont 615S/616S, BASF DE17/PR80/DA18, PPG DP40/DP401 or equivalent. V.O.C. materials would be: DuPont 615S/616S, BASF DE17/PR80/DA18, PPG DCP21/DCP212 or equivalent. 11. Apply two to three medium wet coats of primer surfacer to the entire repair area (including vertical surfaces) of the vehicle, following manufacturer's instructions for application and film build requirements. NOTE: A guide coat Is recommended to highlight high and low spots during the wet or dry sanding process. Typical materials would be: DuPont 1120S/1130S/1125S, BASF DP20/PR80/PH36, PPG K36/DT870/K201 or equivalent. V.O.C. materials would be: DuPont 275S, BASF HP400, PPG DCP21/DCP212 or equivalent. 12. After adequate drying time, wet sand with # 400 grit (or finer) or dry sand with # 320 grit (or finer) sand paper. 13. Repeat steps 6 through 9 and remask the vehicle. 14. Apply a medium coat of primer sealer to the entire repair area. Typical materials would be: DuPont 2610S/2605S, BASF DP21/DH60/PR80, PPG DP40/DP401 or equivalent. V.O.C. materials would be: DuPont 210S, PPG DPW1834 or equivalent. 15. Apply 2 to 3 medium wet coats of basecoat (or until primer is hidden). Follow manufacturer's instructions and recommended dry times. 16. Apply clearcoat. Follow manufacturer's instructions and recommended dry times. 17. After sufficient force dry or air dry time, remove masking. 18. Spot finesse/polish as required. 19. Reinstall previously removed hardware and moldings. HARDWARE ITEM REMOVAL Vehicles have many different hardware options and treatments, but the following list of items can be used as guidelines for item removal. ^ Windshield moldings (non-modular type windows) ^ Back window moldings (non-modular type windows) ^ Side view mirrors (outer panel mounted) ^ Ft. door belt seal strips (doors without window frames) ^ Name plates on fenders, doors, quarters, fascias and deck lids ^ Antenna base (power or fixed mast types) ^ Wiper arms (on vehicles with cowl grilles) ^ Cowl vent grille ^ Fender marker lamps Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 5775 ^ Tail lamps ^ Rocker aero molding emblems ^ Roof weld seam moldings ^ Auxiliary weatherstrips ^ Deck lid lock cyl. cover ^ Wheel opening moldings ^ Roof drip scalp moldings ^ Door edge guards* ^ Spoilers* ^ Luggage racks* ^ Hood grills/ornaments* ^ Decals* ^ Stripes* ^ Body side moldings if mechanically retained. If adhesive retained, mask molding. NOTE: Only items marked with an asterisk are "add" conditions to the Major Operation being performed. Removal time for the other Items listed is included in the allowance. LABOR OPERATION: A6110 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 5776 TIME ALLOWANCE: See Chart That Follows (**) NOTE: The time allowances provided on the chart includes the hardware removal and installation (as indicated by the list guidelines), the masking and unmasking of the vehicle, clearcoat removal (as indicated by the guidelines), the refinish (and colorcoat when required), mix time for primer/paint and clearcoat, finesse/polish where required, washing and preparing the vehicle for delivery. Technical Service Bulletin # 923310 Date: 911101 Paint - Acid Rain Damage to Base Coat/Clear Coat Number: 92-33-10 Section: 10 Date: NOV. 1991 Corporate Bulletin No.: 131060 ASE No.: B2 Subject: INDUSTRIAL FALLOUT/RAIL DUST DAMAGE TO BASE COAT/CLEAR COAT Model and Year: 1983-92 ALL PASSENGER CARS AND TRUCKS Application: 1992 (and previous) models with Base Coat/Clear Coat Paint The following information regards the use of finesse type repairs to environmental (industrial fallout) and rail dust damage of base coat/clear coat paint Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 5777 finishes. Since the severity of the condition varies from area to area, PROPER DIAGNOSIS of the damage extent is CRITICAL TO THE SUCCESS OF REPAIRS. Diagnosis should be performed under high intensity fluorescent lighting, on horizontal surfaces (hood, roof, decklid) after they have been properly cleaned. INDUSTRIAL FALLOUT (ACID RAIN) There are three basic types of acid rain damage: Surface level contamination, - may be repaired by simply washing the vehicle, cleaning the surface with a wax and grease remover, neutralizing acidic residue and finesse polishing. - Clearcoat etching, - slight etching still noticeable after the above washing and finesse polishing procedure. - Basecoat etching, - severe etching beyond the clearcoat into the basecoat. PROCEDURES FOR SURFACE LEVEL CONTAMINATION REPAIRS 1. Wash the vehicle with standard car detergent and water and dry thoroughly. 2. Clean the affected area with a wax and grease remover. 3. Neutralize any left over acidic residue by cleaning the damaged areas with a mixture of baking soda and water (one tablespoon per quart of water), rinse THOROUGHLY and dry the panels completely. 4. Apply a finesse type polish with a foam pad. CLEAN AND INSPECT THE SURFACE A. If the damage has been repaired, remove any swirl marks with a dual action orbital polisher and foam pad. B. If some damage remains, proceed to step 5. SLIGHT CLEARCOAT DAMAGE - WET SANDING, FINESSE POLISHING 5. Select a small test area on a damaged panel. 6. Wet sand the damaged area with an American Grade ultra fine sandpaper of 1,500 to 2,000 grit and a rubber sponge sanding block. During the wet sand process; a. Use ample amounts of water b. Go slow to prevent removing too much clearcoat. Note: Be sure to use American Sandpaper. European Sandpaper has a "P" before the grit number and European grits do not align with American grits the majority of the time. 7. Remove the excess water with a rubber squeegee and inspect the area. A. If this has repaired the damage, continue the sanding procedure on the entire panel, apply a finesse type polish with a foam pad and remove any swirl marks with a dual action orbital polisher and foam pad. B. If (during the repair) it is suspected or observed that; - etching has penetrated into the base coat OR - too much clearcoat has been removed during sanding OR - base color is transferred to pad during polishing, The AFFECTED AREAS MAY REQUIRE RECLEARCOATING/COLORCOATING OR REFINISHING. 8. In any case, once the proper repairs have been made, the final step in the repair process involves polishing the vehicle. A WORD ABOUT CLEARCOAT THICKNESS The clearcoat on the vehicle is typically 1.5 to 2.0 mils thick (one mil equals .001" or 1/1,000 of an inch). At least one mil thickness is required to provide lasting protection to the vehicle basecoat. PAINT GAGES The best way to accurately measure how much clearcoat has been removed is to use a paint gage before, during and after the sanding process. Paint gages measure the total thickness of the finish and when used, can determine how much clearcoat has been removed during the repair process. Paint gages range from magnetic pull types to sophisticated electronic types, are available from a variety of sources, and can cost from $30 to $1800. The older magnetic type gages, at best, a +/- 5% accuracy range and are not sensitive enough to detect removal of .5 mil clearcoat. The newer type magnetic gages have improved accuracy ranges. Most gages are confined to checking either a ferrous metal (steel) or non-ferrous metal (aluminum) panels. At this time, there are no viable gages for reading film thickness on non-metallic panels. A more sophisticated gage is the digital Elcometer 300 fn Paint Thickness gage (or equivalent). It has an ability to read film thickness on both ferrous Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 5778 and non-ferrous metal panels. This instrument has an accuracy range of +/- 1% and has thickness standards included for recalibration. Approximate cost = $1750. An alternative (for use on steel panels only) would be the digital Elcometer 246 model, or equivalent. This gage has a +/- 3% accuracy range and include thickness standards for recalibration. Approximate cost - $575. REPAIRING RAIL DUST DAMAGE Rail dust damage comes from the tiny iron particles produced from the friction between the train wheels and the track. It can also be deposited on vehicles if stored near any operation producing iron dust (steel ore yards, etc.). This dust can either lay on top of, or embed into the paint surface. It is usually diagnosed as; bumps in the paint surface OR - rust colored spots in the paint. PROCEDURE: 1. Wash the vehicle with soap and water, dry it and clean the affected area with wax and grease remover. 2. Keeping the vehicle in a cool or shaded area, rinse the surface with cold water. 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 IT, USE THE NECESSARY SAFETY EQUIPMENT, INCLUDING GLOVES AND GOGGLES. FOLLOW THE MANUFACTURER'S DIRECTIONS CLOSELY BECAUSE IT MAY REQUIRE SPECIAL HANDLING AND DISPOSAL. 3. Soak several terry cloth towels in a container of rail dust remover solution and, after the damaged areas have been rinsed with cold water, lay the wet towels on the damaged areas. 4. Allow the towels to remain in place for 20 minutes, keeping them moist by spraying with water and not allowing to dry on the surface of the vehicle. 5. After 20 minutes of applying the towels, remove them and rinse the area thoroughly with cold water. Inspect the affected area to ensure the dust has been removed. Use both touch (feeling for bumpy surface) and sight (magnifying glass for close inspection). 6. If upon inspection some particles are still present, the process of applying the towels can be repeated 3 times. 7. Select a test area and hand wet sand with American ultra fine 1,500 grit to 2,000 grit sandpaper to repair damage (surface pitting from dust). a. Use ample amounts of water. b. Go slow to prevent removing too much clearcoat. NOTICE: USE A PAINT GAGE TO DETERMINE THE AMOUNT OF CLEARCOAT REMOVED. IF TOO MUCH HAS BEEN REMOVED, ADDITIONAL CLEARCOAT WILL HAVE TO BE APPLIED. IF RAIL DUST HAS PENETRATED INTO THE BASECOAT, THE PANEL REQUIRES REFINISHING. MAKE SURE ALL RAIL DUST HAS BEEN REMOVED PRIOR TO REFINISHING OR THE RUST SPOTS WILL RETURN, CAUSING CUSTOMER COMEBACKS. 8. If the damage has been repaired, complete the repair to the entire panel. 9. Once the damage has been repaired, the final step in the repair process involves polishing the vehicle. PREVENTING INDUSTRIAL FALLOUT DAMAGE Customers should be urged to wash and dry their vehicles frequently and garage them, or at least cover them with a quality car cover when not in use. Vehicles in dealer inventories should be kept clean and dry. A vehicle that sits unattended, especially after the sun has dried any water on the body surface, is a target for acid rain damage. MATERIALS DESCRIBED IN THIS BULLETIN* WAX AND GREASE REMOVER - USE BELOW OR EQUIVALENT Dupont # 3919S, PPG # DX440, BASF # 900, SIKKENS # 6041 FINESSE POLISHES - USE BELOW OR EQUIVALENT Dupont # 1500S, 3000S; BASF # 563-808, 560-1502; PPG # DRX10; 3M PERFECT-IT * USE V.O.C. EQUIVALENTS IN STATES WITH V.O.C. RESTRICTIONS RAIL DUST REMOVER - USE BELOW OR EQUIVALENT Industrial Fallout Remover # 5029 Zep Corporation Atlanta, GA. Telephone # 404-352-1680 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 5779 Stain Away # HBY 0160 Hornby Chemical Milwaukee, WI. Telephone # 414-462-2833 If the rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. PAINT GAGES - USE BELOW OR EQUIVALENT Elcometer Inc. 1893 Rochester Ind. Drive Rochester Hills, MI. 48309 (800) 521-0635 or (313) 650-0500 Zelcro, Ltd./Zormco 8520 Garfield Rd. Cleveland, OH 44125 (216) 441-6102 Delfesko Corp. 410 Cedar St. Ogdensburg, NY 13669 (800) 267-0607 or (613) 925-5987 Pro Motorcar Products Inc. 22025 US-19 North Clearwater, FL 34625 (800) 323-1090 (813) 726-9225 "We believe these sources and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources." Technical Service Bulletin # 331708 Date: 931101 Paint - Clearcoat Degradation, Chalking and Whitening Group Ref.: Body Bulletin No.: 331708 Date: November, 1993 SUBJECT: CLEARCOAT DEGRADATION - CHALKING AND WHITENING MODELS: PASSENGER CARS WITH BASECOAT/CLEARCOAT CONDITION: The vehicle exterior surface may show large chalky or white patches in the clearcoat, usually but not limited to the horizontal surfaces. Blacks, Dark Blues, Reds, may have potential for this condition. On rare occasions, other colors may be involved. CAUSE: The clearcoat (with sunlight and heat) may degrade and turn white or chalky. IDENTIFICATION: On a clean surface, at or above room temperature, firmly apply a 2" wide piece of masking tape to the chalky or white area of the clearcoat and pull upward quickly. The adhesive side of the tape WILL NOT HAVE THE PAINT COLOR ON IT. A light shine or reduced tackiness may be noticed on the tape adhesive surface, indicating clearcoat transfer to the tape. CORRECTION: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 5780 Refinish all horizontal surfaces using the following procedure. - Remove the clearcoat layer from all horizontal surfaces and the top surfaces of fenders and quarter panels. NOTE: In some cases, it will be necessary to remove the clearcoat from the upper vertical surfaces of fenders, doors and quarters (approximately 3"), and the top areas directly above the front and rear wheelhouse openings. - Lightly sand any previously exposed base color to remove any chalky residue from the surface. - The vertical surfaces should be sanded and colorcoated to the next lower breakline (typically the body side moldings) for color uniformity of the repair. IMPORTANT: The following procedure covers clearcoat degradation only. It does not address any other paint condition. PROCEDURE: 1. Some vehicle components will be removed, while others will require masking. The list located at the end of this bulletin will establish the removal items. Items not found on the list and non repair areas are to be masked. 2. Prior to removing the paint finish, clean the area to be refinished with soap and water, followed by an appropriate wax and grease remover. 3. Mask the remaining moldings and hardware for protection during sanding. 4. Remove the clearcoat material from all horizontal surfaces (and tops of fenders and quarters) using a DA (dual action orbital sander) and # 120 grit sanding discs. Lightly sand any previously exposed base color to remove any chalky residue from the surface. NOTE: Chemical stripping is not recommended because of negative Impact to moldings, non-metal components, ELPO and environmental concerns. 5. Lightly sand the unaffected vertical panels to the next lower breakline, smooth and "featheredge" the surface to be refinished with # 240 or # 320 grit sandpaper for maximum adhesion. 6. Blow off the sanding dust and residue. 7. Remove masking tape and remask all necessary areas for priming. 8. Wipe and clean repair area with an appropriate wax and grease remover. 9. Wipe repair area with a tack rag. 10. Apply a coat of self etching or epoxy primer to the bare metal areas exposed during the sanding process. Follow manufacturer's instructions and recommended dry times. Typical materials would be: DuPont 615S/616S, BASF DE17/PR80/DA18, PPG DP40/DP401 or equivalent. V.O.C. materials would be: DuPont 615S/616S, BASF DE17/PR80/DA18, PPG DCP21/DCP212 or equivalent. 11. Apply two to three medium wet coats of primer surfacer to the entire repair area (including vertical surfaces) of the vehicle, following manufacturer's instructions for application and film build requirements. NOTE: A guide coat Is recommended to highlight high and low spots during the wet or dry sanding process. Typical materials would be: DuPont 1120S/1130S/1125S, BASF DP20/PR80/PH36, PPG K36/DT870/K201 or equivalent. V.O.C. materials would be: DuPont 275S, BASF HP400, PPG DCP21/DCP212 or equivalent. 12. After adequate drying time, wet sand with # 400 grit (or finer) or dry sand with # 320 grit (or finer) sand paper. 13. Repeat steps 6 through 9 and remask the vehicle. 14. Apply a medium coat of primer sealer to the entire repair area. Typical materials would be: DuPont 2610S/2605S, BASF DP21/DH60/PR80, PPG DP40/DP401 or equivalent. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 5781 V.O.C. materials would be: DuPont 210S, PPG DPW1834 or equivalent. 15. Apply 2 to 3 medium wet coats of basecoat (or until primer is hidden). Follow manufacturer's instructions and recommended dry times. 16. Apply clearcoat. Follow manufacturer's instructions and recommended dry times. 17. After sufficient force dry or air dry time, remove masking. 18. Spot finesse/polish as required. 19. Reinstall previously removed hardware and moldings. HARDWARE ITEM REMOVAL Vehicles have many different hardware options and treatments, but the following list of items can be used as guidelines for item removal. ^ Windshield moldings (non-modular type windows) ^ Back window moldings (non-modular type windows) ^ Side view mirrors (outer panel mounted) ^ Ft. door belt seal strips (doors without window frames) ^ Name plates on fenders, doors, quarters, fascias and deck lids ^ Antenna base (power or fixed mast types) ^ Wiper arms (on vehicles with cowl grilles) ^ Cowl vent grille ^ Fender marker lamps ^ Tail lamps ^ Rocker aero molding emblems ^ Roof weld seam moldings ^ Auxiliary weatherstrips ^ Deck lid lock cyl. cover ^ Wheel opening moldings ^ Roof drip scalp moldings ^ Door edge guards* ^ Spoilers* ^ Luggage racks* ^ Hood grills/ornaments* ^ Decals* ^ Stripes* ^ Body side moldings if mechanically retained. If adhesive retained, mask molding. NOTE: Only items marked with an asterisk are "add" conditions to the Major Operation being performed. Removal time for the other Items listed is included in the allowance. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 5782 LABOR OPERATION: A6110 TIME ALLOWANCE: See Chart That Follows (**) NOTE: The time allowances provided on the chart includes the hardware removal and installation (as indicated by the list guidelines), the masking and unmasking of the vehicle, clearcoat removal (as indicated by the guidelines), the refinish (and colorcoat when required), mix time for primer/paint and clearcoat, finesse/polish where required, washing and preparing the vehicle for delivery. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > Folding Top Rear Side Rail - Removal and Installation Convertible Top Frame: Technical Service Bulletins Folding Top Rear Side Rail - Removal and Installation Group Ref.: 10 - Body Bulletin No.: 431029 Date: June, 1994 SERVICE MANUAL UPDATE SUBJECT: SECTION 10 - TO ADD FOLDING TOP REAR SIDE RAIL REMOVAL AND INSTALLATION PROCEDURE MODELS: 1986-94 CHEVROLET CAVALIER 1986-94 PONTIAC SUNBIRD This bulletin is being issued to add the folding top rear side rail removal and installation procedure not previously provided in Section 10 of the appropriate Service Manual. REMOVE OR DISCONNECT: (Refer to illustration) 1. Clevis pin attaching cylinder to rear side rail. 2. Quarter window weatherstrip retainer (do not remove 3 lower nuts attaching weatherstrip to rear side rail). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > Folding Top Rear Side Rail - Removal and Installation > Page 5789 3. Bottom and top tension cables. 4. Bow # 3 from rear side rail. 5. Front side rail from rear side rail. 6. Bow # 4 link from rear side rail. 7. Rear side rail lower pivot bolt. 8. Inner arm upper pivot bolt. 9. Rear side rail. 10. Quarter window weatherstrip from rear side rail. INSTALL OR CONNECT: (Refer to illustration) Note: Tighten all bolts and nuts to 20.3 N-m (15 lbs.ft.). Tighten all screws until fully seated, fastened, not stripped. 1. Lower 3 nuts attaching quarter window weatherstrip to rear side rail. 2. Rear side rail. 3. Rear side rail lower pivot bolt. 4. Clevis pin attaching cylinder to rear side rail. Use a cotter pin to secure the clevis pin. DO NOT reuse the hairpin clip if used. 5. Front side rail to rear side rail. 6. Position folding top halfway up. 7. Bow # 4 link to rear side rail. 8. Inner arm upper pivot bolt. 9. Bow # 3 to rear side rail. 10. Bottom and top tension cables. 11. Quarter window weatherstrip retainer. 12. Quarter window weatherstrip. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > Folding Top Rear Side Rail - Removal and Installation > Page 5790 Convertible Top Frame: Technical Service Bulletins Convertible Top Pinch Weld - Accessibility Number: 93-140-10 Section: 10 Date: MARCH 1993 Corporate Bulletin No.: 331007 ASE No.: B1 Subject: CONVERTIBLE PINCH WELD ACCESSIBILITY Model and Year: 1984-93 CAMARO 1984-89 CAVALIER 1991-93 CAVALIER SERVICE UPDATE This bulletin is being issued to inform dealers that the pinch welds on the rocker panels have been covered by a reinforcement and cannot be utilized effectively to facilitate frame pulling/straightening. Thus, it will be necessary for the repair technician to obtain or create pinch weld tabs. These tabs are to be placed on the inboard forward and rearward ends of the rocker reinforcement. These tabs can be purchased through GM Dealer Equipment and come in two styles, "L" and "T" types. The "T" type is recommended for convertible applications. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Convertible Top > Convertible Top Frame > Component Information > Technical Service Bulletins > Folding Top Rear Side Rail - Removal and Installation > Page 5791 If the technician needs to create "T" type weld-on tabs, the technician must obtain eight 12" (305 mm) long by 3/4" (19 mm) by 1/2" (13 mm) and 5/8" (16 mm) thick angle iron. The technician will then need to drill eight (8) holes to facilitate plug welding. These holes should be 3/8" (10 mm) in diameter and should be done to all eight (8) pieces of steel. Next, take two (2) pieces of angle iron (with the drilled holes at the top) and mig weld both pieces together. Now, weld these tabs to the inboard/forward and rearward edge of the rocker reinforcement as per illustration. Anchoring can now be accomplished using either process through normal unibody equipment. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Technical Service Bulletins > Webasto Sunroof System - Information Hotline Sunroof / Moonroof: Technical Service Bulletins Webasto Sunroof System - Information Hotline Group Ref.: Body Bulletin No.: 431018A Date: May, 1994 INFORMATION SUBJECT: VEHICLES EQUIPPED WITH A WEBASTO SUNROOF SYSTEM MODELS: 1987-94 BUICK MODELS 1987-94 CADILLAC MODELS 1988-94 CHEVROLET MODELS 1987-94 OLDSMOBILE MODELS 1986-94 PONTIAC MODELS THIS BULLETIN IS BEING REVISED TO INCLUDE CHEVROLET AND PONTIAC VEHICLES. PLEASE DISCARD BULLETIN 431018. Webasto Sunroof Corporation has established a hotline for information pertaining to parts or serviceability of Webasto sunroofs. Call 1-800-995-5911 with any questions concerning these issues. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 5805 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 5806 - 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 5807 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 5808 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 5809 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 5810 Seat Cover: Technical Service Bulletins Leather Seat Covers - Cleaning Procedure File In Section: 10 - Body Bulletin No.: 43-16-06 Date: October, 1994 Subject: Cleaning Procedure for Leather Seat Covers Models: 1995 and Prior Passenger Cars and "C/K" and "S/T" Trucks If leather seat covers are being returned only because they are dirty, a more aggressive cleaning procedure is recommended by General Motors prior to replacing covers. Procedure Dirty or soiled leather seat covers should be cleaned with a mild soap and water solution, using clean soft cloths. When this procedure proves inadequate, a commercially available leather cleaner, "Tanner's Preserve Leather Cleaner"* should be used with a 3M "Type T"* scrubbing pad. Important: The type of scrubbing pad is very critical because the common 3M Scotch-Brite green pad is too aggressive and will damage the leather finish. The cleaner is available from "First Brands" by calling 1-800-726-1001, identifying yourself as a GM dealership, requesting "Tanner's Preserve Leather Cleaner" product, number AS-330, quantity and shipping address. This product is also available at stores. The 3M "Type T" scrubbing pad is available from a 3M distributor. Call 1-800-742-9546 for the nearest distributor and then request the Scotch-Brite Clean and Finish Sheet, "Type T", in 6 x 9 inch sheets, UPC code number 048011-01276. * We believe these sources and their equipment to be reliable. There may be additional manufacturers of such equipment. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or for any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Customer Interest for Seat Latch: > 9133510 > May > 91 > Seat (Passenger) - Will Not Lock Into Position Seat Latch: Customer Interest Seat (Passenger) - Will Not Lock Into Position Number: 91-335-10 Section: 10 Date: MAY 1991 Corporate Bulletin No.: 131025 Subject: PASSENGER SEAT WILL NOT LOCK INTO POSITION Model and Year: 1989-91 CAVALIER COUPE Models Affected: 1989 through early 1991 J Coupe, Models, except Cavalier Models with Value Leader Package. Condition: The standard passenger seat EZ Entry seat adjuster for 1989-1991 J coupe models may exhibit a no-lock condition when repositioning the seat assembly forward or backward. Cause: The latch return spring on the outer track of the seat adjuster may break when adjusting the seat assembly forward or backward. Once the spring is broken, the latch on the outer track cannot return to the lock position. Correction: Replace passenger seat outer latch return spring as follows: Remove or Disconnect: 1. Seat adjuster trim covers. 2. Seat adjuster-to-floor pan attaching nuts, then remove seat assembly from vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Customer Interest for Seat Latch: > 9133510 > May > 91 > Seat (Passenger) - Will Not Lock Into Position > Page 5819 3. Outer latch return spring from latch and track (Figure 1). Install or Connect: 1. Outer latch return spring, P/N 12510770 to latch and track (Figure 1). 2. Seat assembly into vehicle and install seat adjuster-to-floor pan attaching nuts. Tighten nuts to 29 N-m. (21 lbs.ft.). 3. Seat adjuster trim covers. Parts are currently available from GMSPO. Labor Operation Number: T1730 Labor Time: .3 Hour Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Latch: > 9133510 > May > 91 > Seat (Passenger) - Will Not Lock Into Position Seat Latch: All Technical Service Bulletins Seat (Passenger) - Will Not Lock Into Position Number: 91-335-10 Section: 10 Date: MAY 1991 Corporate Bulletin No.: 131025 Subject: PASSENGER SEAT WILL NOT LOCK INTO POSITION Model and Year: 1989-91 CAVALIER COUPE Models Affected: 1989 through early 1991 J Coupe, Models, except Cavalier Models with Value Leader Package. Condition: The standard passenger seat EZ Entry seat adjuster for 1989-1991 J coupe models may exhibit a no-lock condition when repositioning the seat assembly forward or backward. Cause: The latch return spring on the outer track of the seat adjuster may break when adjusting the seat assembly forward or backward. Once the spring is broken, the latch on the outer track cannot return to the lock position. Correction: Replace passenger seat outer latch return spring as follows: Remove or Disconnect: 1. Seat adjuster trim covers. 2. Seat adjuster-to-floor pan attaching nuts, then remove seat assembly from vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Latch: > 9133510 > May > 91 > Seat (Passenger) - Will Not Lock Into Position > Page 5825 3. Outer latch return spring from latch and track (Figure 1). Install or Connect: 1. Outer latch return spring, P/N 12510770 to latch and track (Figure 1). 2. Seat assembly into vehicle and install seat adjuster-to-floor pan attaching nuts. Tighten nuts to 29 N-m. (21 lbs.ft.). 3. Seat adjuster trim covers. Parts are currently available from GMSPO. Labor Operation Number: T1730 Labor Time: .3 Hour Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 9133510 > May > 91 > Seat (Passenger) - Will Not Lock Into Position Seat Track: Customer Interest Seat (Passenger) - Will Not Lock Into Position Number: 91-335-10 Section: 10 Date: MAY 1991 Corporate Bulletin No.: 131025 Subject: PASSENGER SEAT WILL NOT LOCK INTO POSITION Model and Year: 1989-91 CAVALIER COUPE Models Affected: 1989 through early 1991 J Coupe, Models, except Cavalier Models with Value Leader Package. Condition: The standard passenger seat EZ Entry seat adjuster for 1989-1991 J coupe models may exhibit a no-lock condition when repositioning the seat assembly forward or backward. Cause: The latch return spring on the outer track of the seat adjuster may break when adjusting the seat assembly forward or backward. Once the spring is broken, the latch on the outer track cannot return to the lock position. Correction: Replace passenger seat outer latch return spring as follows: Remove or Disconnect: 1. Seat adjuster trim covers. 2. Seat adjuster-to-floor pan attaching nuts, then remove seat assembly from vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 9133510 > May > 91 > Seat (Passenger) - Will Not Lock Into Position > Page 5834 3. Outer latch return spring from latch and track (Figure 1). Install or Connect: 1. Outer latch return spring, P/N 12510770 to latch and track (Figure 1). 2. Seat assembly into vehicle and install seat adjuster-to-floor pan attaching nuts. Tighten nuts to 29 N-m. (21 lbs.ft.). 3. Seat adjuster trim covers. Parts are currently available from GMSPO. Labor Operation Number: T1730 Labor Time: .3 Hour Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 9133510 > May > 91 > Seat (Passenger) - Will Not Lock Into Position Seat Track: All Technical Service Bulletins Seat (Passenger) - Will Not Lock Into Position Number: 91-335-10 Section: 10 Date: MAY 1991 Corporate Bulletin No.: 131025 Subject: PASSENGER SEAT WILL NOT LOCK INTO POSITION Model and Year: 1989-91 CAVALIER COUPE Models Affected: 1989 through early 1991 J Coupe, Models, except Cavalier Models with Value Leader Package. Condition: The standard passenger seat EZ Entry seat adjuster for 1989-1991 J coupe models may exhibit a no-lock condition when repositioning the seat assembly forward or backward. Cause: The latch return spring on the outer track of the seat adjuster may break when adjusting the seat assembly forward or backward. Once the spring is broken, the latch on the outer track cannot return to the lock position. Correction: Replace passenger seat outer latch return spring as follows: Remove or Disconnect: 1. Seat adjuster trim covers. 2. Seat adjuster-to-floor pan attaching nuts, then remove seat assembly from vehicle. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 9133510 > May > 91 > Seat (Passenger) - Will Not Lock Into Position > Page 5840 3. Outer latch return spring from latch and track (Figure 1). Install or Connect: 1. Outer latch return spring, P/N 12510770 to latch and track (Figure 1). 2. Seat assembly into vehicle and install seat adjuster-to-floor pan attaching nuts. Tighten nuts to 29 N-m. (21 lbs.ft.). 3. Seat adjuster trim covers. Parts are currently available from GMSPO. Labor Operation Number: T1730 Labor Time: .3 Hour Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations Lower Center Portion Of Tailgate Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Technical Service Bulletins > Customer Interest for Spoiler: > 9118910 > Feb > 91 > Aero Molding - Loose/Wavy Edge Spoiler: Customer Interest Aero Molding - Loose/Wavy Edge Number: 91-189-10 Section: 10 Date: February 1991 Corporate Bulletin No.: 071503 Subject: WAVY UPPER EDGE/LOOSE OR NO ENGAGEMENT OF CLIP ON AERO MOLDING Model and Year: 1991 CAVALIER Z24 ONLY CONDITION: Some 1991 Chevrolet Z-24 models may have Aero Moldings that exhibit one of the following conditions: 1. Wavy upper edge 2. Loose or no engagement of clip CORRECTION: Condition # 1 refer to illustration and situation # 1. Remove 2.0 mm (3/32") from the top edge of the clip. Condition # 2 refer to illustration and situation # 2. Remove 2.0 mm (3/32") from the stud openings as indicated and reinstall using 2 self drilling screws at the locations indicated. WARRANTY INFORMATION: Use labor operation B9550 OR B9551 Plus 0.2 hr. straight time Use applicable Labor Time Guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spoiler: > 9118910 > Feb > 91 > Aero Molding Loose/Wavy Edge Spoiler: All Technical Service Bulletins Aero Molding - Loose/Wavy Edge Number: 91-189-10 Section: 10 Date: February 1991 Corporate Bulletin No.: 071503 Subject: WAVY UPPER EDGE/LOOSE OR NO ENGAGEMENT OF CLIP ON AERO MOLDING Model and Year: 1991 CAVALIER Z24 ONLY CONDITION: Some 1991 Chevrolet Z-24 models may have Aero Moldings that exhibit one of the following conditions: 1. Wavy upper edge 2. Loose or no engagement of clip CORRECTION: Condition # 1 refer to illustration and situation # 1. Remove 2.0 mm (3/32") from the top edge of the clip. Condition # 2 refer to illustration and situation # 2. Remove 2.0 mm (3/32") from the stud openings as indicated and reinstall using 2 self drilling screws at the locations indicated. WARRANTY INFORMATION: Use labor operation B9550 OR B9551 Plus 0.2 hr. straight time Use applicable Labor Time Guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak Weatherstrip: Customer Interest Door Glass/Quarter Window Area - Waterleak File In Section: 10 - Body Bulletin No.: 43-15-11 Date: October, 1994 Subject: Waterleak at Door Glass and Quarter Window Area (Diagnostic Service Procedure) Models: 1988-94 Chevrolet Cavalier 1988-94 Pontiac Sunbird (Convertible models only) Caution: To help avoid injury to you or others when raising or lowering the convertible top, keep your hands away from any hinges and linkage and close all latching handles. This bulletin is being issued to help identify potential areas of waterleaks at: A-pillar weatherstrip to front rail weatherstrip, front rail weatherstrip to center rail weatherstrip and center rail weatherstrip to rear rail weatherstrip. Before performing any repair procedures, verify with owner that proper convertible top operating procedures and conditions have been observed as follows: ^ Never raise or lower the top while the car is moving. The wind could get under it and cause damage. ^ If automatic car washes are used, it is recommended that a soft cloth car wash be used and the vehicle climate control system should be set to "vent" and the fan be set at its highest speed. This will prevent the high pressure water from entering around the convertible top. ^ Do not try to lower or raise the convertible top if your vehicle is out in cold weather, 41°F (5°C) or below. The cold can cause cracks and other damage to the convertible top as it is being lowered or raised. ^ Do not lower the convertible top if it is damp or wet. After the convertible top is down, the trapped water can cause stains, mildew and damage to the inside of the vehicle. Be sure to dry off the convertible top before you lower it. ^ Make sure there is nothing in the convertible top storage well (the area behind the rear seat where the convertible top will go) or under the well in the trunk. Even a small item could damage the rear window or convertible top when it is lowered. ^ The convertible top is not designed to carry weight. Never let anyone sit on the convertible top, and do not put anything on top of it when it is up or down, or it could be damaged. ^ All side windows must be partially lowered before lowering or raising convertible top to prevent weatherstrip and seal damage or displacement which could result in water and/or wind leaks. Gathering detailed information from the vehicle owner is a valuable tool in locating and repairing water leaks. It may be necessary to ask leading questions to the location and conditions when water leaks occur. Some helpful questions may be asked as follows: 1. What area of the vehicle does water appear? 2. Does water leak occur when it rains? 3. Does water leak occur when vehicle is washed? 4. Is vehicle washed in an automatic car wash or is it washed by hand? 5. Have seals or weatherstrips been serviced previously? 6. Have door or quarter windows been serviced previously? 7. Has vehicle been in a collision at any time? As an aid in diagnosIng waterleaks, the following video should be reviewed: "Pontiac Tech Track Sunbird Convertible Wlndnoise and Water Leak Diagnosis and AlIgnment". The vehicle should be visually inspected and watertested wIth water test stands as described in Section 10-1 of the appropriate Service Manual. Check and adjust quarter glass alignment if necessary. Refer to Section 10-7 of the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak > Page 5867 Check and adjust door glass to quarter glass alignment if necessary. Refer to Sections 10-6 and 10-7 of the appropriate Service Manual. Check and adjust convertible top alignment if necessary. Refer to Section 10-9 of the appropriate Service Manual. Condition 1. Permanent damage to weatherstrips at A-pillar, front rail, center rail and/or rear rail such as: ^ Hole in weatherstrip (refer to Figure 1). ^ Extensively deformed (refer to Figure 1). ^ Torn or badly distorted (refer to Figure 1). 2. Waterleak found between weatherstrip retainer and A-pillar, front rail, center rail or rear rail. 3. Waterleak found between A-pillar weatherstrip to folding top front seal assembly has two potential conditions identified: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak > Page 5868 ^ Gaping (refer to Figure 2). ^ Puckering (refer to Figure 2). 4. Waterleak found between front rail weatherstrip to center rail weatherstrip has two potential conditions identified: ^ Gaping (Refer to Figure 3). ^ Puckering (Refer to Figure 3). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak > Page 5869 5. Waterleak found between center rail weatherstrip to rear rail weatherstrip has three potential conditions identified: ^ Gaping (Refer to Figure 4). ^ Puckering (Refer to Figure 4). ^ Rolling (Refer to Figure 4). Correction Note: When correction procedures are complete, apply a thin coat of petroleum jelly or silicone to sides of center rail weatherstrip and rear rail weatherstrip Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak > Page 5870 to reduce weatherstrip rolling. Refer to Figure 5. 1. Damaged weatherstrips to be replaced. Refer to procedures in Section 10-9 of the appropriate Service Manual. 2. Repair weatherstrip retainer. Refer to procedures in Section 10-9 of the appropriate Service Manual. 3. To correct A-pillar weatherstrip to front rail weatherstrip gaping, use the following procedure: 1. Remove approximately 100 mm (4.0 inch) of weatherstrip from top of A-pillar retainer. 2. Using black weatherstrip adhesive, P/N 12345097, or equivalent, install weatherstrip into A-pillar retainer while pulling weatherstrip upward until contacting front rail weatherstrip end. Refer to Figure 6. 3A. To correct A-pillar weatherstrip to folding top front seal assembly puckering, use the following procedure: 1. Lower convertible top about halfway. 2. Remove approximately 100 mm (4.0 inch) of weatherstrip from top of A-pillar retainer. 3. Remove approximately 100 mm (4.0 inch) of folding top front seal assembly from across No. 1 bow and down front side rail retainer. 4. Install stuffers (two each end) into the cut-away in back of weatherstrips. Refer to Figure 7. This will push the weatherstrip surface back to its original shape. 5. Using black weatherstrip adhesive, P/N 12345097, or equivalent, install weatherstrip into A-pillar retainer. 6. Using black weatherstrip adhesive, P/N 12345097, or equivalent, install folding top front seal assembly. 7. Raise convertible top and lock. 4. To correct front rail weatherstrip to center rail weatherstrip gaping, use the following procedure: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak > Page 5871 1. Remove center rail weatherstrip retaining screw. Refer to Figure 8. 2. Remove front rail weatherstrip retaining screw. Refer to Figure 8. 3. Remove approximately 100 mm (4.0 inch) of weatherstrip from rear to center of front retainer. 4. Remove approximately 100 mm (4.0 inch) of weatherstrip from front to center of center retainer. 5. Using black weatherstrip adhesive, P/N 12345097, or equivalent, install front and center rail weatherstrips into retainer, pulling ends together until contacting. Refer to Figure 8. 6. Install front and center rail weatherstrip retaining screws. Refer to Figure 8. 4A. To correct front rail weatherstrip to center rail weatherstrip puckering, use the following procedure. 1. Lower convertible top about halfway. 2. Remove center rail weatherstrip retaining screw. Refer to Figure 8. 3. Remove front rail weatherstrip retaining screw. Refer to Figure 8. 4. Remove approximately 100 mm (4.0 inch) of weatherstrip from rear to center of front retainer. 5. Remove approximately 100 mm (4.0 inch) of weatherstrip from front to center of center retainer. 6. Install stuffers (two each end) into the cut-away in back of weatherstrips. Refer to Figure 7. This will push the weatherstrip surface back to its original shape. 7. Raise convertible top and lock. 8. Using black weatherstrip adhesive, PIN 12345097, or equivalent, install front and center rail weatherstrips into retainer, pulling ends together until contacting. Refer to Figure 8. 9. Install front and center rail weatherstrip retaining screws. Refer to Figure 8. 5. To correct center rail weatherstrip to rear rail weatherstrip gaping, use the following procedure: 1. Lower convertible top about halfway. 2. Lower quarter window. 3. Remove center rail weatherstrip retaining screw. 4. Remove approximately 1OO mm (4.0 inch) of weatherstrip from front to center of retainer. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak > Page 5872 5. Relocate center rail weatherstrip retaining screw hole forward 4 - 5 mm (0.156 - 0.203 inch). Refer to Figure 9. 6. Using black weatherstrip adhesive, P/N 12345097, or equivalent, install center rail weatherstrip forward in retainer. 7. Install center rail weatherstrip retaining screw into new hole. Refer to Figure 9. 8. Perform watertest. If waterleak is still existing, proceed to step 9. 9. Remove center portion of center rail weatherstrip, approximately 25 mm (1.0 inch) from retainer ends. Refer to Figure 10. 10. Apply black weatherstrip adhesive, P/N 12345097, or equivalent, in retainer. 11. Install center rail weatherstrip into retainer while pushing weatherstrip rearward. Refer to Figure 10. 5A. To correct center rail weatherstrip to rear rail weatherstrip puckering, use the following procedure: 1. Lower convertible top about halfway. 2. Lower quarter window. 3. Remove center rail weatherstrip approximately 100 mm (4.0 inch) from the rear joint end by disconnecting clip. 4. Install stuffers (two) into the cut-away in back of center rail weatherstrip. Refer to Figure 7. This will push the weatherstrip surface back to its original shape. 5. Apply black weatherstrip adhesive, P/N 12345097, or equivalent, in retainer. 6. Install center rail weatherstrip into retainer. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak > Page 5873 5B. To correct center rail weatherstrip to rear rail weatherstrip rolling, use the following procedure: 1. Lower convertible top about halfway. 2. Lower quarter window. 3. Remove center rail weatherstrip retaining screw. Refer to Figure 11. 4. Remove approximately 100 mm (4.0 inch) of weatherstrip from front to center of retainer. 5. Apply black weatherstrip adhesive, P/N 12345097, or equivalent, in retainer. 6. Install center rail weatherstrip into retainer while pushing weatherstrip rearward 3 - 4 mm (0.118 0.157 inch). Refer to Figure 11. 7. Install center rail weatherstrip retaining screw. 8. Perform watertest. If waterleak is still existing, proceed to step 9. 9. Remove center portion of center rail weatherstrip approximately 25 mm (1.0 inch) from retainer ends. Refer to Figure 10. 10. Apply black weatherstrip adhesive, P/N 12345097, or equivalent, in retainer. 11. Install center rail weatherstrip into retainer while pushing weatherstrip rearward. Refer to Figure 10. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Seal, center to rear rail Labor Operation Labor Time B3110 (Right) 0.3 hr. B3111 (Left) 0.3 hr. Seal, side rail weatherstrip Labor Operation Labor Time B3140 (Right) 0.3 hr. B3141 (Left) 0.3 hr. Seal, rear rail (rear roof rail weatherstrip) Labor Operation Labor Time B3150 (Right) 0.3 hr. B3151 (Left) 0.3 hr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-08-64-016C > Jul > 09 > Body - Maintaining Exterior Weatherstrip Appearance Weatherstrip: All Technical Service Bulletins Body - Maintaining Exterior Weatherstrip Appearance INFORMATION Bulletin No.: 99-08-64-016C Date: July 29, 2009 Subject: Information on Maintaining Exterior Weatherstrip Appearance 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 add model years and update the parts and procedure information. Please discard Corporate Bulletin Number 99-08-64-016B (Section 08 - Body and Accessories). Exterior weatherstrips are exposed to a variety of environmental elements, including UV rays, acid rain, insect and bird residue and atmospheric fallout. All of these may effect the appearance of the weatherstrips; however, they do not effect the functionality of the weatherstrip. Weatherstrips that are discolored should not be replaced under the normal GM New Vehicle Warranty. Weatherstrip Maintenance Instructions Silicone grease on weatherstrips will make them last longer, seal better, and not stick or squeak. Clean the weatherstrips with a mild soap and water solution. Apply silicone grease with a clean cloth. During very cold, damp weather, frequent application may be required. Refer to the information below for the recommended maintenance products. Weatherstrips that are not maintained may crack and weather due to environmental elements. Parts Information Weatherstrip Conditioning Weatherstrip Lubricant (GM P/N 3634770 [in Canada, P/N 10953518]) or Dielectric Silicone Grease (GM P/N 12345579 [in Canada, P/N 992887]). Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak Weatherstrip: All Technical Service Bulletins Door Glass/Quarter Window Area - Waterleak File In Section: 10 - Body Bulletin No.: 43-15-11 Date: October, 1994 Subject: Waterleak at Door Glass and Quarter Window Area (Diagnostic Service Procedure) Models: 1988-94 Chevrolet Cavalier 1988-94 Pontiac Sunbird (Convertible models only) Caution: To help avoid injury to you or others when raising or lowering the convertible top, keep your hands away from any hinges and linkage and close all latching handles. This bulletin is being issued to help identify potential areas of waterleaks at: A-pillar weatherstrip to front rail weatherstrip, front rail weatherstrip to center rail weatherstrip and center rail weatherstrip to rear rail weatherstrip. Before performing any repair procedures, verify with owner that proper convertible top operating procedures and conditions have been observed as follows: ^ Never raise or lower the top while the car is moving. The wind could get under it and cause damage. ^ If automatic car washes are used, it is recommended that a soft cloth car wash be used and the vehicle climate control system should be set to "vent" and the fan be set at its highest speed. This will prevent the high pressure water from entering around the convertible top. ^ Do not try to lower or raise the convertible top if your vehicle is out in cold weather, 41°F (5°C) or below. The cold can cause cracks and other damage to the convertible top as it is being lowered or raised. ^ Do not lower the convertible top if it is damp or wet. After the convertible top is down, the trapped water can cause stains, mildew and damage to the inside of the vehicle. Be sure to dry off the convertible top before you lower it. ^ Make sure there is nothing in the convertible top storage well (the area behind the rear seat where the convertible top will go) or under the well in the trunk. Even a small item could damage the rear window or convertible top when it is lowered. ^ The convertible top is not designed to carry weight. Never let anyone sit on the convertible top, and do not put anything on top of it when it is up or down, or it could be damaged. ^ All side windows must be partially lowered before lowering or raising convertible top to prevent weatherstrip and seal damage or displacement which could result in water and/or wind leaks. Gathering detailed information from the vehicle owner is a valuable tool in locating and repairing water leaks. It may be necessary to ask leading questions to the location and conditions when water leaks occur. Some helpful questions may be asked as follows: 1. What area of the vehicle does water appear? 2. Does water leak occur when it rains? 3. Does water leak occur when vehicle is washed? 4. Is vehicle washed in an automatic car wash or is it washed by hand? 5. Have seals or weatherstrips been serviced previously? 6. Have door or quarter windows been serviced previously? 7. Has vehicle been in a collision at any time? As an aid in diagnosIng waterleaks, the following video should be reviewed: "Pontiac Tech Track Sunbird Convertible Wlndnoise and Water Leak Diagnosis and AlIgnment". The vehicle should be visually inspected and watertested wIth water test stands as described in Section 10-1 of the appropriate Service Manual. Check and adjust quarter glass alignment if necessary. Refer to Section 10-7 of the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak > Page 5883 Check and adjust door glass to quarter glass alignment if necessary. Refer to Sections 10-6 and 10-7 of the appropriate Service Manual. Check and adjust convertible top alignment if necessary. Refer to Section 10-9 of the appropriate Service Manual. Condition 1. Permanent damage to weatherstrips at A-pillar, front rail, center rail and/or rear rail such as: ^ Hole in weatherstrip (refer to Figure 1). ^ Extensively deformed (refer to Figure 1). ^ Torn or badly distorted (refer to Figure 1). 2. Waterleak found between weatherstrip retainer and A-pillar, front rail, center rail or rear rail. 3. Waterleak found between A-pillar weatherstrip to folding top front seal assembly has two potential conditions identified: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak > Page 5884 ^ Gaping (refer to Figure 2). ^ Puckering (refer to Figure 2). 4. Waterleak found between front rail weatherstrip to center rail weatherstrip has two potential conditions identified: ^ Gaping (Refer to Figure 3). ^ Puckering (Refer to Figure 3). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak > Page 5885 5. Waterleak found between center rail weatherstrip to rear rail weatherstrip has three potential conditions identified: ^ Gaping (Refer to Figure 4). ^ Puckering (Refer to Figure 4). ^ Rolling (Refer to Figure 4). Correction Note: When correction procedures are complete, apply a thin coat of petroleum jelly or silicone to sides of center rail weatherstrip and rear rail weatherstrip Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak > Page 5886 to reduce weatherstrip rolling. Refer to Figure 5. 1. Damaged weatherstrips to be replaced. Refer to procedures in Section 10-9 of the appropriate Service Manual. 2. Repair weatherstrip retainer. Refer to procedures in Section 10-9 of the appropriate Service Manual. 3. To correct A-pillar weatherstrip to front rail weatherstrip gaping, use the following procedure: 1. Remove approximately 100 mm (4.0 inch) of weatherstrip from top of A-pillar retainer. 2. Using black weatherstrip adhesive, P/N 12345097, or equivalent, install weatherstrip into A-pillar retainer while pulling weatherstrip upward until contacting front rail weatherstrip end. Refer to Figure 6. 3A. To correct A-pillar weatherstrip to folding top front seal assembly puckering, use the following procedure: 1. Lower convertible top about halfway. 2. Remove approximately 100 mm (4.0 inch) of weatherstrip from top of A-pillar retainer. 3. Remove approximately 100 mm (4.0 inch) of folding top front seal assembly from across No. 1 bow and down front side rail retainer. 4. Install stuffers (two each end) into the cut-away in back of weatherstrips. Refer to Figure 7. This will push the weatherstrip surface back to its original shape. 5. Using black weatherstrip adhesive, P/N 12345097, or equivalent, install weatherstrip into A-pillar retainer. 6. Using black weatherstrip adhesive, P/N 12345097, or equivalent, install folding top front seal assembly. 7. Raise convertible top and lock. 4. To correct front rail weatherstrip to center rail weatherstrip gaping, use the following procedure: Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak > Page 5887 1. Remove center rail weatherstrip retaining screw. Refer to Figure 8. 2. Remove front rail weatherstrip retaining screw. Refer to Figure 8. 3. Remove approximately 100 mm (4.0 inch) of weatherstrip from rear to center of front retainer. 4. Remove approximately 100 mm (4.0 inch) of weatherstrip from front to center of center retainer. 5. Using black weatherstrip adhesive, P/N 12345097, or equivalent, install front and center rail weatherstrips into retainer, pulling ends together until contacting. Refer to Figure 8. 6. Install front and center rail weatherstrip retaining screws. Refer to Figure 8. 4A. To correct front rail weatherstrip to center rail weatherstrip puckering, use the following procedure. 1. Lower convertible top about halfway. 2. Remove center rail weatherstrip retaining screw. Refer to Figure 8. 3. Remove front rail weatherstrip retaining screw. Refer to Figure 8. 4. Remove approximately 100 mm (4.0 inch) of weatherstrip from rear to center of front retainer. 5. Remove approximately 100 mm (4.0 inch) of weatherstrip from front to center of center retainer. 6. Install stuffers (two each end) into the cut-away in back of weatherstrips. Refer to Figure 7. This will push the weatherstrip surface back to its original shape. 7. Raise convertible top and lock. 8. Using black weatherstrip adhesive, PIN 12345097, or equivalent, install front and center rail weatherstrips into retainer, pulling ends together until contacting. Refer to Figure 8. 9. Install front and center rail weatherstrip retaining screws. Refer to Figure 8. 5. To correct center rail weatherstrip to rear rail weatherstrip gaping, use the following procedure: 1. Lower convertible top about halfway. 2. Lower quarter window. 3. Remove center rail weatherstrip retaining screw. 4. Remove approximately 1OO mm (4.0 inch) of weatherstrip from front to center of retainer. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak > Page 5888 5. Relocate center rail weatherstrip retaining screw hole forward 4 - 5 mm (0.156 - 0.203 inch). Refer to Figure 9. 6. Using black weatherstrip adhesive, P/N 12345097, or equivalent, install center rail weatherstrip forward in retainer. 7. Install center rail weatherstrip retaining screw into new hole. Refer to Figure 9. 8. Perform watertest. If waterleak is still existing, proceed to step 9. 9. Remove center portion of center rail weatherstrip, approximately 25 mm (1.0 inch) from retainer ends. Refer to Figure 10. 10. Apply black weatherstrip adhesive, P/N 12345097, or equivalent, in retainer. 11. Install center rail weatherstrip into retainer while pushing weatherstrip rearward. Refer to Figure 10. 5A. To correct center rail weatherstrip to rear rail weatherstrip puckering, use the following procedure: 1. Lower convertible top about halfway. 2. Lower quarter window. 3. Remove center rail weatherstrip approximately 100 mm (4.0 inch) from the rear joint end by disconnecting clip. 4. Install stuffers (two) into the cut-away in back of center rail weatherstrip. Refer to Figure 7. This will push the weatherstrip surface back to its original shape. 5. Apply black weatherstrip adhesive, P/N 12345097, or equivalent, in retainer. 6. Install center rail weatherstrip into retainer. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 431511 > Oct > 94 > Door Glass/Quarter Window Area - Waterleak > Page 5889 5B. To correct center rail weatherstrip to rear rail weatherstrip rolling, use the following procedure: 1. Lower convertible top about halfway. 2. Lower quarter window. 3. Remove center rail weatherstrip retaining screw. Refer to Figure 11. 4. Remove approximately 100 mm (4.0 inch) of weatherstrip from front to center of retainer. 5. Apply black weatherstrip adhesive, P/N 12345097, or equivalent, in retainer. 6. Install center rail weatherstrip into retainer while pushing weatherstrip rearward 3 - 4 mm (0.118 0.157 inch). Refer to Figure 11. 7. Install center rail weatherstrip retaining screw. 8. Perform watertest. If waterleak is still existing, proceed to step 9. 9. Remove center portion of center rail weatherstrip approximately 25 mm (1.0 inch) from retainer ends. Refer to Figure 10. 10. Apply black weatherstrip adhesive, P/N 12345097, or equivalent, in retainer. 11. Install center rail weatherstrip into retainer while pushing weatherstrip rearward. Refer to Figure 10. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use: Seal, center to rear rail Labor Operation Labor Time B3110 (Right) 0.3 hr. B3111 (Left) 0.3 hr. Seal, side rail weatherstrip Labor Operation Labor Time B3140 (Right) 0.3 hr. B3141 (Left) 0.3 hr. Seal, rear rail (rear roof rail weatherstrip) Labor Operation Labor Time B3150 (Right) 0.3 hr. B3151 (Left) 0.3 hr. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Weatherstrip: > 99-08-64-016C > Jul > 09 > Body - Maintaining Exterior Weatherstrip Appearance Weatherstrip: All Technical Service Bulletins Body - Maintaining Exterior Weatherstrip Appearance INFORMATION Bulletin No.: 99-08-64-016C Date: July 29, 2009 Subject: Information on Maintaining Exterior Weatherstrip Appearance 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 add model years and update the parts and procedure information. Please discard Corporate Bulletin Number 99-08-64-016B (Section 08 - Body and Accessories). Exterior weatherstrips are exposed to a variety of environmental elements, including UV rays, acid rain, insect and bird residue and atmospheric fallout. All of these may effect the appearance of the weatherstrips; however, they do not effect the functionality of the weatherstrip. Weatherstrips that are discolored should not be replaced under the normal GM New Vehicle Warranty. Weatherstrip Maintenance Instructions Silicone grease on weatherstrips will make them last longer, seal better, and not stick or squeak. Clean the weatherstrips with a mild soap and water solution. Apply silicone grease with a clean cloth. During very cold, damp weather, frequent application may be required. Refer to the information below for the recommended maintenance products. Weatherstrips that are not maintained may crack and weather due to environmental elements. Parts Information Weatherstrip Conditioning Weatherstrip Lubricant (GM P/N 3634770 [in Canada, P/N 10953518]) or Dielectric Silicone Grease (GM P/N 12345579 [in Canada, P/N 992887]). Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Combination Cruise/Stop Light Switch Brake Switch (Cruise Control): Description and Operation Combination Cruise/Stop Light Switch A separately mounted vacuum release valve is used with this combination switch. When the brake pedal is depressed, the switch resets the cruise function to a non-cruise condition and illuminates the brake lights. Two sets of electrical contacts are used in the switch: one to operate the stop lights, and the other to operate the cruise release function. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Combination Cruise/Stop Light Switch > Page 5900 Brake Switch (Cruise Control): Description and Operation Combination Vacuum Release Valve/Converter Clutch Switch This combination valve and switch is used on vehicles equipped with a lock-up torque converter. The vacuum release valve portion operates identically to the release valve previously described. At the same time, the converter clutch switch contacts open and the locking clutch mechanism in the transmission is disengaged. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 5901 Brake Switch (Cruise Control): Testing and Inspection An inoperative valve must be replaced. Ensure vacuum hose to switch is firmly connected and that it is not cracked or deteriorated. Vacuum source and hoses should be checked for improper routing, leaks, kinks or restrictions. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Description and Operation Clutch Switch: Description and Operation The clutch switch is used on vehicles equipped with manual transmission. When the clutch pedal is depressed, the cruise function is disconnected and will remain so after the pedal is released. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Behind LH Side Of I/P, Near Top Of Shroud Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 5908 Cruise Control Module: Description and Operation The module will interpret the position of the servo, the position of the control switches and the output of the speed sensor. In response to these inputs, the module electrically signals the opening or closing of the vent and vacuum solenoid valves in the servo. The module is mounted on the dash support bracket at the right side of the steering column, but is integral with the ECM on some models with certain engines. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Servo: > 921078A > Feb > 92 > Cruise Control - Intermittent Dropout/Fail to Set/Resume Cruise Control Servo: Customer Interest Cruise Control - Intermittent Dropout/Fail to Set/Resume Number: 92-107-8A Section: 8A Date: FEB. 1992 Corporate Bulletin No.: 239001 ASE No.: A8 Subject: CRUISE CONTROL INTERMITTENT DROP-OUT AND/OR FAIL TO SET OR RESUME Model and Year: 1988-92 ALL PASSENGER CARS AND TRUCKS EXCEPT CAPRICE IS 1988-90 ONLY CONDITION: On 1988-92 vehicles using the vacuum servo cruise control system, the cruise control may intermittently lose speed and/or drop-out (release), while using cruise control. It may also fail to initially set, or resume, at times. Vehicles using the Electro-Motor Cruise Control system (Stepper Motor Cruise) are not affected. When driving the vehicle, the cruise control will operate normally for 10 to 30 miles, then may gradually lose speed and/or drop out of cruise. If you experience this condition, accelerate to a speed higher than the cruise set speed, using the accelerator pedal only. DO NOT use the set or resume controls. Then allow the vehicle to coast down, and see whether the cruise catches and holds at the set speed. If the cruise catches and holds at the set speed, the diagnostic procedure below should be used to test the servo and vacuum system. Because of the intermittent nature of this condition, you may have to try several times to reproduce this condition. CAUSE: In a small percentage of servos, the vent valve, which normally cycles to control the amount of vacuum needed to maintain a set speed, may fail to close at times. When this happens, the vacuum is being continually vented, so the servo cannot pull the throttle open to increase the vehicle speed. The valve may close correctly the next time the cruise is cycled by setting or resuming. Because this condition is intermittent, testing the vehicle following the Service Manual diagnostic procedures may lead to the replacement of good parts, which will not correct the vehicle. This may lead to the customer having to bring the vehicle back for service again. It is recommended that the following diagnostic procedure be performed to determine if the trouble can be found. DIAGNOSTIC PROCEDURE: First evaluate the cruise system as specified in the Service Manual. Then make the following additional checks that may detect conditions with the vacuum portion of the cruise system. Source Vacuum Check: Disconnect the vacuum supply hose from the servo (small hose). Install a vacuum gage at the hose end and start the engine. The gage should read at least 10 in. Hg. (34 Kp/m2). If there is no vacuum, or very little vacuum, inspect for leaking or pinched hoses. Servo Vacuum Valve Check: With engine off, remove the vacuum supply hose (small hose) from the servo. Using a hand held vacuum pump connected to the vacuum port on the servo, stroke the pump until the gage reads 10-15 in.Hg. (34 - 50 Kp/m2). Replace the servo if either of the following conditions occur: 1. Vacuum valve will not hold any vacuum. 2. Gage reads 10-15 in.HG. (34 - 50 Kp/m2), but vacuum may decrease quickly (less than 10 seconds). In a good servo, the vacuum may decrease slowly (more than 30 seconds). Servo Vent Valve Check: Disconnect the servo from the throttle linkage. Disconnect the electrical connector from the servo. Using a fused jumper wire, apply 12 volts to terminal "A" on the servo. Connect a jumper wire from terminal "C" on the servo to ground. You should hear a click noise as the vent valve closes. Remove the vacuum release valve hose (large hose) from the servo. Using a hand held vacuum pump connected to the large port, stroke the pump until the servo diaphragm pulls in and the gage reads 10-20 in.Hg. (34 - 68 Kp/m2). Replace the servo if either of the following conditions occur: 1. Diaphragm will not move in completely. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Servo: > 921078A > Feb > 92 > Cruise Control - Intermittent Dropout/Fail to Set/Resume > Page 5917 2. Diaphragm moves in completely. Gauge reads 10-15 in.Hg. (34 - 50 Kp/m2), but vacuum decreases quickly (In a good servo the vacuum may decrease slowly). Vacuum Release Valve (On Brake Pedal) Check: Disconnect the vacuum release hose from the servo (large hose). Apply vacuum (10-20 in.Hg. (34-68 Kp/m2)) to the hose using a hand vacuum pump and gage. The vacuum reading on the gage should remain steady. If gage reading does not hold, or leaks down slowly, inspect for a leaking or misadjusted vacuum release valve (at the brake pedal), or a leaking hose. A leaking vacuum release system will dramatically effect the operation and life of the servo. Other items that could affect servo life and operation are: - Improper servo cable or rod adjustment; - Binding throftle linkage; - Loose or bent servo bracket; or - Poor electrical connections. If the previous diagnostic procedures fail to determine the cause of the cruise system intermittent condition, replace the servo. WARRANTY INFORMATION: Use Labor Operation T1821, Labor Time: 0.5 hrs., for diagnostic time only Use existing labor operations for replacement of parts. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo: > 921078A > Feb > 92 > Cruise Control - Intermittent Dropout/Fail to Set/Resume Cruise Control Servo: All Technical Service Bulletins Cruise Control - Intermittent Dropout/Fail to Set/Resume Number: 92-107-8A Section: 8A Date: FEB. 1992 Corporate Bulletin No.: 239001 ASE No.: A8 Subject: CRUISE CONTROL INTERMITTENT DROP-OUT AND/OR FAIL TO SET OR RESUME Model and Year: 1988-92 ALL PASSENGER CARS AND TRUCKS EXCEPT CAPRICE IS 1988-90 ONLY CONDITION: On 1988-92 vehicles using the vacuum servo cruise control system, the cruise control may intermittently lose speed and/or drop-out (release), while using cruise control. It may also fail to initially set, or resume, at times. Vehicles using the Electro-Motor Cruise Control system (Stepper Motor Cruise) are not affected. When driving the vehicle, the cruise control will operate normally for 10 to 30 miles, then may gradually lose speed and/or drop out of cruise. If you experience this condition, accelerate to a speed higher than the cruise set speed, using the accelerator pedal only. DO NOT use the set or resume controls. Then allow the vehicle to coast down, and see whether the cruise catches and holds at the set speed. If the cruise catches and holds at the set speed, the diagnostic procedure below should be used to test the servo and vacuum system. Because of the intermittent nature of this condition, you may have to try several times to reproduce this condition. CAUSE: In a small percentage of servos, the vent valve, which normally cycles to control the amount of vacuum needed to maintain a set speed, may fail to close at times. When this happens, the vacuum is being continually vented, so the servo cannot pull the throttle open to increase the vehicle speed. The valve may close correctly the next time the cruise is cycled by setting or resuming. Because this condition is intermittent, testing the vehicle following the Service Manual diagnostic procedures may lead to the replacement of good parts, which will not correct the vehicle. This may lead to the customer having to bring the vehicle back for service again. It is recommended that the following diagnostic procedure be performed to determine if the trouble can be found. DIAGNOSTIC PROCEDURE: First evaluate the cruise system as specified in the Service Manual. Then make the following additional checks that may detect conditions with the vacuum portion of the cruise system. Source Vacuum Check: Disconnect the vacuum supply hose from the servo (small hose). Install a vacuum gage at the hose end and start the engine. The gage should read at least 10 in. Hg. (34 Kp/m2). If there is no vacuum, or very little vacuum, inspect for leaking or pinched hoses. Servo Vacuum Valve Check: With engine off, remove the vacuum supply hose (small hose) from the servo. Using a hand held vacuum pump connected to the vacuum port on the servo, stroke the pump until the gage reads 10-15 in.Hg. (34 - 50 Kp/m2). Replace the servo if either of the following conditions occur: 1. Vacuum valve will not hold any vacuum. 2. Gage reads 10-15 in.HG. (34 - 50 Kp/m2), but vacuum may decrease quickly (less than 10 seconds). In a good servo, the vacuum may decrease slowly (more than 30 seconds). Servo Vent Valve Check: Disconnect the servo from the throttle linkage. Disconnect the electrical connector from the servo. Using a fused jumper wire, apply 12 volts to terminal "A" on the servo. Connect a jumper wire from terminal "C" on the servo to ground. You should hear a click noise as the vent valve closes. Remove the vacuum release valve hose (large hose) from the servo. Using a hand held vacuum pump connected to the large port, stroke the pump until the servo diaphragm pulls in and the gage reads 10-20 in.Hg. (34 - 68 Kp/m2). Replace the servo if either of the following conditions occur: 1. Diaphragm will not move in completely. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo: > 921078A > Feb > 92 > Cruise Control - Intermittent Dropout/Fail to Set/Resume > Page 5923 2. Diaphragm moves in completely. Gauge reads 10-15 in.Hg. (34 - 50 Kp/m2), but vacuum decreases quickly (In a good servo the vacuum may decrease slowly). Vacuum Release Valve (On Brake Pedal) Check: Disconnect the vacuum release hose from the servo (large hose). Apply vacuum (10-20 in.Hg. (34-68 Kp/m2)) to the hose using a hand vacuum pump and gage. The vacuum reading on the gage should remain steady. If gage reading does not hold, or leaks down slowly, inspect for a leaking or misadjusted vacuum release valve (at the brake pedal), or a leaking hose. A leaking vacuum release system will dramatically effect the operation and life of the servo. Other items that could affect servo life and operation are: - Improper servo cable or rod adjustment; - Binding throftle linkage; - Loose or bent servo bracket; or - Poor electrical connections. If the previous diagnostic procedures fail to determine the cause of the cruise system intermittent condition, replace the servo. WARRANTY INFORMATION: Use Labor Operation T1821, Labor Time: 0.5 hrs., for diagnostic time only Use existing labor operations for replacement of parts. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Page 5924 Cruise Control Servo: Locations LH Rear Of Engine Compartment LH Rear Of Engine Compartment, On Strut Tower LH Rear Of Engine Compartment. LH Rear Of Engine Compartment, On Strut Tower Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Page 5925 Cruise Control Servo: Description and Operation Fig. 1 Servo Unit The servo unit, Fig. 1, operates the throttle in response to signals from the electronic controller. During a steady speed cruise condition, both vacuum and vent valves are closed or sealed. The servo holds a constant vacuum on the diaphragm and places no flow requirements on the vacuum source. During vehicle deceleration, the vacuum solenoid is energized by the controller to open vacuum valve to vacuum source. Throttle angle is increased by increased vacuum level in the servo, and the vent remains closed. During vehicle acceleration, the vent solenoid is de-energized by the controller to open the vent valve to atmosphere. This reduces vacuum in the servo and allows throttle return spring to decrease throttle angle while the vacuum valve remains closed. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Testing and Inspection > Test C: Servo Resistance Test Fig. 37 Servo Resistance Test C Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Testing and Inspection > Test C: Servo Resistance Test > Page 5928 Cruise Control Servo: Testing and Inspection Test O: Servo Actuation Test If VSS light does not illuminate, or voltage between terminals A and D remains less than 7 volts check for open in red wire (circuit 381) from the engine control module . Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Testing and Inspection > Test C: Servo Resistance Test > Page 5929 Fig. 38 Servo Actuation Test S Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Vacuum Vent Solenoid > Component Information > Description and Operation > Vacuum Release Valve Cruise Control Vacuum Vent Solenoid: Description and Operation Vacuum Release Valve The vacuum release valve provides an additional vent to atmosphere for the servo unit when the brake pedal is held in the depressed position. The venting is spring actuated and occurs within the free travel of the brake pedal arm. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Vacuum Vent Solenoid > Component Information > Description and Operation > Vacuum Release Valve > Page 5934 Cruise Control Vacuum Vent Solenoid: Description and Operation Combination Vacuum Release Valve/Converter Clutch Switch This combination valve and switch is used on vehicles equipped with a lock-up torque converter. The vacuum release valve portion operates identically to the release valve previously described. At the same time, the converter clutch switch contacts open and the locking clutch mechanism in the transmission is disengaged. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Behind LH Side Of I/P, Near Top Of Shroud Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 5939 Cruise Control Module: Description and Operation The module will interpret the position of the servo, the position of the control switches and the output of the speed sensor. In response to these inputs, the module electrically signals the opening or closing of the vent and vacuum solenoid valves in the servo. The module is mounted on the dash support bracket at the right side of the steering column, but is integral with the ECM on some models with certain engines. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Combination Cruise/Stop Light Switch Brake Switch (Cruise Control): Description and Operation Combination Cruise/Stop Light Switch A separately mounted vacuum release valve is used with this combination switch. When the brake pedal is depressed, the switch resets the cruise function to a non-cruise condition and illuminates the brake lights. Two sets of electrical contacts are used in the switch: one to operate the stop lights, and the other to operate the cruise release function. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Combination Cruise/Stop Light Switch > Page 5945 Brake Switch (Cruise Control): Description and Operation Combination Vacuum Release Valve/Converter Clutch Switch This combination valve and switch is used on vehicles equipped with a lock-up torque converter. The vacuum release valve portion operates identically to the release valve previously described. At the same time, the converter clutch switch contacts open and the locking clutch mechanism in the transmission is disengaged. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 5946 Brake Switch (Cruise Control): Testing and Inspection An inoperative valve must be replaced. Ensure vacuum hose to switch is firmly connected and that it is not cracked or deteriorated. Vacuum source and hoses should be checked for improper routing, leaks, kinks or restrictions. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Description and Operation Clutch Switch: Description and Operation The clutch switch is used on vehicles equipped with manual transmission. When the clutch pedal is depressed, the cruise function is disconnected and will remain so after the pedal is released. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Vacuum Pump, Cruise Control > Component Information > Adjustments Vacuum Pump: Adjustments Switch assembly and valve assembly cannot be adjusted until brake booster pushrod is assembled to brake pedal assembly. Adjustment is as follows: 1. Depress brake pedal and switch assembly and valve assembly into their proper retaining clips until fully seated. 2. On vehicles equipped with anti-lock brakes, release brake pedal and allow to come to rest. 3. On models less ABS brakes, slowly pull pedal back to its fully retracted position. The switch assembly and valve assembly will move within their retainers to their adjusted position. 4. The following brake pedal travel distances may be used to check for a properly adjusted cruise control and stop lamp switch assembly and vacuum release valve assembly. a. Cruise control switch contacts must open at 1/8 to 1/2 inch pedal travel, measured at centerline of brake pedal pad. Nominal actuation of stop lamp contacts is 3/16 inch after cruise control contacts open. b. Vacuum release valve assembly must open at 1 1/16 to 1 5/16 inches pedal travel, measured at centerline of brake pedal pad. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Locations Vacuum Vent Valve: Locations Below LH Side Of I/P. Behind I/P, On Brake Pedal Support Applicable to: Cavalier w/Automatic Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Service and Repair Brake Warning Indicator: Service and Repair This lamp will be illuminated when the ignition switch is placed in the ON position. The lamp may be illuminated for as long as 30 seconds as a bulb and system check. If the lamp remains illuminated or comes on while operating the vehicle, a problem in the ANTILOCK brake system is indicated. When lamp is illuminated, place the ignition switch in OFF position, then restart engine. If lamp still remains illuminated, the anti-lock brake system should be serviced. The brake system will remain functional, without the anti-lock function. After servicing the anti-lock system the lamp will automatically reset. On some models it may be necessary to operate vehicle at a speed over 18 mph to reset lamp. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5964 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5965 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5966 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5967 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5968 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5969 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5970 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5971 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5972 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5973 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5974 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5975 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5976 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5977 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5978 Cigarette Lighter: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5979 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5980 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5981 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5982 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5983 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 5984 Interior Lights: Cigarlighter/I/P Compartment/Luggage Compartment/Cargo Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation Some vehicles use a buzzer or indicator lamp to indicate a low coolant level condition. The buzzer or lamp is activated by a sensor, located in the radiator, when the coolant level becomes one quart or more low. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Lamp > Component Information > Description and Operation > Page 5988 Coolant Level Indicator Lamp: Service and Repair This lamp will be illuminated when engine coolant level in the radiator drops below a pre-determined level. To turn lamp "OFF," check cooling system, then add coolant to bring system to proper level. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling the SIR System Air Bag(s) Arming and Disarming: Service and Repair Disabling the SIR System The diagnostic energy reserve module (DERM) can maintain voltage to cause a system deployment for up to ten minutes after the ignition switch is turned off and the battery is disconnected. Servicing the SIR system during this period may result in accidental deployment and personal injury. 1. Ensure front wheels are pointed straight ahead. 2. Turn ignition switch to Lock position and remove SIR or AIRBAG fuse. 3. Remove lower left sound insulator. 4. Remove connector position assurance (CPA) lock and disconnect yellow two-way SIR harness connector at base of steering column. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling the SIR System > Page 5994 Air Bag(s) Arming and Disarming: Service and Repair Enabling the SIR System 1. Connect yellow two-way SIR harness connector and install CPA lock. 2. Install left sound insulator. 3. Install SIR fuse. 4. Turn ignition switch to Run position and ensure ``Inflatable Restraint'' lamp flashes 7-9 times and then remains off. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Panel Dimmer Switch Dimmer Switch: Locations Panel Dimmer Switch Behind LH Side Of I/P LH side of I/P, near LH front speaker Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations > Panel Dimmer Switch > Page 6001 Behind LH Side Of I/P Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6004 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6005 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6006 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6007 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6008 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6009 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6010 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6011 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6012 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6013 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6014 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6015 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6016 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6017 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6018 Dimmer Switch: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6019 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6020 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6021 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6022 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6023 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6024 Dimmer Switch: Electrical Diagrams Interior Lights Dimming Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6025 Interior Lights Dimming Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations Door Switch: Locations In Respective Front Door Latch Assembly Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation Fuel Gauge: Description and Operation The fuel gauge system consists of a sending unit, instrument voltage regulator and an electric fuel gauge. The sending unit is a variable resistor that is controlled by a float. Corresponding to actual fuel level, the float will rise or fall. When the ignition is turned to the On position, voltage is applied to the gauge through the voltage regulator, completing the gauge ground circuit through the sending unit. When the tank is full and the float is raised, maximum resistance (approximately 90 ohms) is produced by the sending unit, current flow through the gauge is decreased, and the gauge pointer moves slightly. As the tank empties and the float drops resistance in the sending unit decreases, current flow through the gauge increases and the gauge pointer moves toward empty. Most analog fuel gauges are of the free floating type, which means that the gauge pointer does not remain against the full stop when the ignition is off. Rather, the pointer floats to a mid-position when no voltage is applied to the gauge. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Page 6032 Fuel Gauge: Testing and Inspection Gauge Reads Empty When Tank Is Full This condition is generally caused by a short in the fuel tank unit circuit. 1. Disconnect electrical connector to sending unit, then turn ignition switch to ON position. 2. If gauge reads past full, test gauge with tester BT-6508 or equivalent. If gauge reads empty, disconnect main body harness connector, near the fuse block. 3. If gauge still shows empty, check for short in printed circuit or defective gauge. If gauge reads beyond full, reconnect front body harness connector and disconnect rear body harness connector (in left wheel house). 4. If gauge shows empty, locate and repair grounded wire in harness between front and rear body harness connectors. If gauge reads beyond full, check for short between rear body harness connector, damaged float or defective sending unit. Gauge Reads Full Or Beyond At All Times This condition is generally caused by an open in the tank unit circuit. 1. Check tank unit ground for proper contact with body or chassis and repair as needed. 2. If tank unit ground is satisfactory, disconnect electrical connector to tank unit and connect harness side of connector to suitable ground with jumper wire, then turn on ignition. 3. If gauge reads empty, remove fuel tank and inspect wiring to sending unit. If wiring and connections are satisfactory, replace tank unit. 4. If gauge still shows full, disconnect front body harness connector and ground fuel gauge wire terminal in instrument panel side of connector. 5. If gauge still reads full, check for loose connection in cluster, open (crack) in printed circuit or defective gauge. If gauge reads empty, locate and repair open or poor connection between front body connector and tank unit connector. Fuel Gauge Inaccurate Tester BT-6508 or equivalent must be used to diagnose dash gauge malfunction. 1. Ensure battery is fully charged, disconnect electrical connector to tank unit and connect tester to between harness connector and suitable ground following manufacturer's instructions. 2. Set tester on empty then turn on ignition. Gauge should read empty or below. 3. Set tester on full. Gauge should read full or above. 4. If gauge does not respond to tester input, replace dash gauge. If gauge responds correctly, check for poor connections at tank unit, poor tank unit ground or defective tank unit. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fuel Tank Unit And Lines (Typical) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6036 Fuel Pump/Fuel Gauge Sending Unit (typical) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6037 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit (typical) REMOVAL: 1. Before servicing the fuel pump the fuel system pressure must be relieved, see MAINTENANCE PROCEDURES. 2. Disconnect the negative battery cable. 3. Raise the car on a hoist. 4. Remove the fuel tank, 5. Remove the fuel tank sending unit and pump assembly by turning the cam lock ring counterclockwise. Lift assembly from the fuel tank. 6. Pull the fuel pump up into the attaching hose while pulling outward away from the bottom support. Take care to prevent damage to the rubber insulator and strainer during removal. After the pump assembly is clear of the bottom support, pull the pump assembly out of the rubber connector for removal. NOTE: Inspect the fuel pump attaching hose for any signs of deterioration. Also check the rubber sound insulator at the bottom of the pump. Replace damaged or deteriorated parts. INSTALLATION: 1. Push the fuel pump assembly into the attaching hose. 2. Position the fuel tank sending unit and pump assembly into the fuel tank. Use a new "O" ring seal. NOTE: Care should be taken not to fold over or twist the strainer when installing the sending unit as this will restrict the flow of fuel. Also, verify that the strainer does not block the full travel of the float arm. 3. Install cam lock over the assembly and lock by turning clockwise. 4. Reinstall fuel tank. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6038 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling the SIR System Air Bag(s) Arming and Disarming: Service and Repair Disabling the SIR System The diagnostic energy reserve module (DERM) can maintain voltage to cause a system deployment for up to ten minutes after the ignition switch is turned off and the battery is disconnected. Servicing the SIR system during this period may result in accidental deployment and personal injury. 1. Ensure front wheels are pointed straight ahead. 2. Turn ignition switch to Lock position and remove SIR or AIRBAG fuse. 3. Remove lower left sound insulator. 4. Remove connector position assurance (CPA) lock and disconnect yellow two-way SIR harness connector at base of steering column. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling the SIR System > Page 6044 Air Bag(s) Arming and Disarming: Service and Repair Enabling the SIR System 1. Connect yellow two-way SIR harness connector and install CPA lock. 2. Install left sound insulator. 3. Install SIR fuse. 4. Turn ignition switch to Run position and ensure ``Inflatable Restraint'' lamp flashes 7-9 times and then remains off. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation Low Fuel Lamp/Indicator: Description and Operation The switch type consists of an indicator light and a low fuel warning switch located on the instrument panel. The warning switch contacts are closed by the difference in voltage potential between the fuel gauge terminals. This voltage differential will activate the warning switch when the fuel tank is less than 1/4 full and, in turn, cause the indicator to light. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Page 6048 Low Fuel Lamp/Indicator: Testing and Inspection SYMPTOM: Low fuel indicator does not operate correctly, gauge is OK CHECK: Indicator bulb. Repair if necessary. If the bulb is OK, remove the instrument cluster and send it to a service center for repair. Often, a number for a qualified service center may be written on the back of the instrument cluster. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Service and Repair Malfunction Indicator Lamp: Service and Repair The check engine lamp will be illuminated when the ignition switch is placed in the On position. When the engine is started, the lamp should go off. If the lamp remains On for 10 seconds or constantly after the engine is started, the self diagnosis system has detected a problem and has stored a code in the system Electronic Control Module (ECM). After diagnosis and repair, the ECM memory can be cleared of codes as follows: On models except Cadillac with DEFI and 1986-88 Buick Reatta/Riviera and Oldsmobile Toronado/Trofeo, remove the ECM fuse or disconnect the battery ground cable for approximately 30 seconds, with ignition switch in the Off position. It should be noted, if battery ground cable is disconnected to clear codes, components such as clocks, electronically tuned radios etc., will have to be reset. On vehicle that are equipped as such, the ECM power feed is connected by a pigtail, inline fuse holder, at the positive battery terminal. To clear codes within the ECM system and protect the components that need resetting, disconnect the inline fuse. On 1980-85 Cadillac models with DEFI engines, depress Electronic Climate Control Off and Hi buttons to clear codes. On 1986-92 Cadillac DeVille and Fleetwood models, depress Off and Lo button on the Electronic Climate Control to clear stored BCM codes. Depress Off and Hi to clear stored ECM codes. On Cadillac Eldorado and Seville and 1986-88 Buick Reatta/Riviera and Oldsmobile Toronado/Trofeo models, the stored codes are cleared during the self-diagnostic procedure. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Odometer/Speedometer - ACDelco Service Center Locations Odometer: Technical Service Bulletins Odometer/Speedometer - ACDelco Service Center Locations File In Section: 8 - Chassis/Body Electrical Bulletin No.: 66-83-04A Date: September, 1996 INFORMATION Subject: AC Delco Service Center Locations for Odometer/Speedometer Service Models: 1997 and Prior Passenger Cars and Trucks (excluding Cadillac) This bulletin is being revised to provide the necessary contact information only. Please discard Corporate Bulletin Number 66-83-04 (Section 8 - Chassis/Body Electrical) General Motors provides service for sophisticated electronic products through the authorized AC Delco Service Center Program. This program is designed to provide GM vehicle owners with the highest quality and most technically up-to-date product available. Repair products from unauthorized service outlets are not acceptable as warranty replacements. Currently, there are 25 authorized AC Delco Service Centers who exchange and remanufacture odometer/speedometers (list included). Only these Centers should be contacted for service. Important: W series and 1997 T series Medium Duty truck odometer/speedometers must be ordered directly from GMSPO. The following steps should be taken when utilizing the AC Delco Service Centers: Dealers should contact their local AC Delco Service Center (list included). Any listed facility may be used. The following information must be provided: Part number VIN, Mileage, Vehicle Year, Make and Model Dealer Name and Address Delivery Date of Vehicle Name of the person requesting exchange or service Phone number Repair Order Number P.O. number (if non - warranty) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Odometer/Speedometer - ACDelco Service Center Locations > Page 6056 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Odometer/Speedometer - ACDelco Service Center Locations > Page 6057 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Odometer/Speedometer - ACDelco Service Center Locations > Page 6058 AC Delco Service Centers Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High Oil Pressure Gauge: Customer Interest Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High > Page 6067 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High Oil Pressure Gauge: All Technical Service Bulletins Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 91451A8C > Mar > 92 > Oil Pressure Gauge - Flutters/Reads High > Page 6073 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Page 6074 Oil Pressure Gauge: Description and Operation This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuated the contact on the variable resistor, in turn controlling current flow through the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge reading. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Page 6075 Oil Pressure Gauge: Testing and Inspection Disconnect the oil pressure gauge lead from the sending unit, connect a 12 volt test lamp between the gauge lead and the ground and turn ignition on. If test lamp flashes, the instrument voltage regulator is functioning properly and the gauge circuit is not broken. If the test lamp remains lit, the instrument voltage regulator is defective and must be replaced. If the test lamp does not light, check the instrument voltage regulator for proper ground or an open circuit. Also, check for an open in the instrument voltage regulator to oil pressure gauge wire or in the gauge itself. If test lamp flashes and gauge is not accurate, the gauge may be out of calibration, requiring replacement. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest: > 91451A8C > Mar > 92 > Oil Pressure Gauge Flutters/Reads High Oil Pressure Sender: Customer Interest Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest: > 91451A8C > Mar > 92 > Oil Pressure Gauge Flutters/Reads High > Page 6084 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91451A8C > Mar > 92 > Oil Pressure Gauge Flutters/Reads High Oil Pressure Sender: All Technical Service Bulletins Oil Pressure Gauge - Flutters/Reads High Number: 91-451A-8C Section: 8C Date: MARCH 1992 Corporate Bulletin No.: 138304R ASE No.: A6 Subject: OIL PRESSURE GAGE FLUTTERS, OR MAY READ HIGH Model and Year: 1990 CELEBRITY 1990-91 CAPRICE, CAMARO, CAVALIER, CORSICA, BERETTA, LUMINA AND CORVETTE 1990-91 LUMINA (APV) 1990-91 C/K, R/V, S/T, G, M/L, P THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-451-8C, DATED NOVEMBER 1991. PART NUMBER INFORMATION FOR THE P TRUCK HAS BEEN UPDATED AND DIESEL ENGINES ON TRUCKS. ALL COPIES OF 91-451-8C SHOULD BE DISCARDED. Condition: On vehicles with gages, the oil pressure gage may flutter, or may show unusually high oil pressure (full scale). Cause: The internal resistance wire in the sensor may not be properly supported, resulting in an intermittent open condition. Correction: Check for normal causes of high oil pressure gage readings (high resistence or open circuit), such as a poor ground path caused by loose sensor mounting, oil cooler adapter loose, or poor electrical connections. If no cause can be found, replace the oil pressure sensor with the correct new part number from the attached chart. Warranty Information: Use existing labor operation N2220. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91451A8C > Mar > 92 > Oil Pressure Gauge Flutters/Reads High > Page 6090 NEW OIL PRESSURE SENSOR PART NUMBERS 1990-91 Models Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Sender: > 9118910 > Feb > 91 > Aero Molding - Loose/Wavy Edge Spoiler: All Technical Service Bulletins Aero Molding - Loose/Wavy Edge Number: 91-189-10 Section: 10 Date: February 1991 Corporate Bulletin No.: 071503 Subject: WAVY UPPER EDGE/LOOSE OR NO ENGAGEMENT OF CLIP ON AERO MOLDING Model and Year: 1991 CAVALIER Z24 ONLY CONDITION: Some 1991 Chevrolet Z-24 models may have Aero Moldings that exhibit one of the following conditions: 1. Wavy upper edge 2. Loose or no engagement of clip CORRECTION: Condition # 1 refer to illustration and situation # 1. Remove 2.0 mm (3/32") from the top edge of the clip. Condition # 2 refer to illustration and situation # 2. Remove 2.0 mm (3/32") from the stud openings as indicated and reinstall using 2 self drilling screws at the locations indicated. WARRANTY INFORMATION: Use labor operation B9550 OR B9551 Plus 0.2 hr. straight time Use applicable Labor Time Guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > Page 6101 Oil Pressure Sender: Locations Rear Of Engine RH rear of engine, below intake manifold Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation Many cars utilize a warning light on the instrument panel in place of the conventional dash indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is wired in series with the ignition switch and the engine unit, which is an oil pressure switch. The oil pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on, the warning light circuit is energized and the circuit is completed through the closed contacts in the pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm, opening the contacts, thereby breaking the circuit and putting out the light. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 6105 Oil Pressure Warning Lamp/Indicator: Testing and Inspection On some models, the oil pressure indicator light also serves as the electric choke defect indicator. If Oil or engine indicator light does not light, check to ensure electric choke is not disconnected at carburetor. Also check for defect in electric choke heater, blown gauge fuse or defect in lamp or wiring circuit. If indicator light stays on with engine running possible causes are: oil pressure is low, switch to indicator light wiring has an open circuit, oil pressure switch wire connector has disconnected or on some models, gauge or radio fuse has blown. The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. The presence of sealing compound on the threads of the engine unit will cause a poor ground. If the warning light remains lit when it normally should be out, replace the engine unit before proceeding to determine the cause for a low pressure indication. The warning light sometimes will light up or will flicker when the engine is idling, even though the oil pressure is adequate. However, the light should go out when the engine speed is increased. There is no cause for alarm in such cases; it simply means that the pressure switch is not calibrated precisely correct. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > Customer Interest for A/T Shift Indicator Module: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned A/T Shift Indicator Module: Customer Interest A/T - Shift Indicator Misaligned Number: 91-458-7A Section: 7A Date: DEC. 1991 Corporate Bulletin No.: 138305 ASE No.: A2 Subject: SHIFT INDICATOR MISALIGNED Model and Year: 1991 CAVALIER WITH AUTOMATIC TRANSMISSION Condition: Shift indicator may come out of adjustment. Cause: Adjuster did not "collapse" on indicator tape during production, thus creating a low ratcheting effort. Correction: Replace console trim plate with updated part. Refer to "Parts Information" for updated part number. Refer to Section 8C for replacement procedure. Parts Information: 22575236 Trim plate assembly - with power windows 22575237 Trim plate assembly - without power windows Parts are currently available from GMSPO. Warranty Information: Labor Operation Number: K5100 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/T Shift Indicator Module: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned A/T Shift Indicator Module: All Technical Service Bulletins A/T - Shift Indicator Misaligned Number: 91-458-7A Section: 7A Date: DEC. 1991 Corporate Bulletin No.: 138305 ASE No.: A2 Subject: SHIFT INDICATOR MISALIGNED Model and Year: 1991 CAVALIER WITH AUTOMATIC TRANSMISSION Condition: Shift indicator may come out of adjustment. Cause: Adjuster did not "collapse" on indicator tape during production, thus creating a low ratcheting effort. Correction: Replace console trim plate with updated part. Refer to "Parts Information" for updated part number. Refer to Section 8C for replacement procedure. Parts Information: 22575236 Trim plate assembly - with power windows 22575237 Trim plate assembly - without power windows Parts are currently available from GMSPO. Warranty Information: Labor Operation Number: K5100 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > Warnings and Alarm - Update Test Procedure Seat Belt Reminder Lamp: Technical Service Bulletins Warnings and Alarm - Update Test Procedure Number: 91-301-8A Section: 8A Date: MAY 1991 Corporate Bulletin No.: 138108 Subject: WARNINGS AND ALARM UPDATE TEST PROCEDURE Model and Year: 1990-91 CAVALIER SUBJECT UPDATE 1990 and 1991 ALL J CARLINES 1. The Fasten Belts Indicator test needs to be updated to reflect a fault in the Automatic Safety Belt circuit. If the Fasten Belts indicator remains lit after performing test "D" in Section 8A-76, check for an opening in the 528 ckt between term "B" of the Multi-Function Alarm Module and splice S237. 2. The circuit operation for the Fasten Belts Indicator needs to include the statement: The Fasten Belts indicator will remain lit if there is a fault in the Automatic Safety Belt circuit. Please note your copies of the above Service Manuals. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Testing and Inspection > Test D: Fasten Belts Indicator Test Fig. 17 Automatic Safety Belt Diagnosis, Fasten Belts Indicator Test Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Testing and Inspection > Test D: Fasten Belts Indicator Test > Page 6126 Fig. 18 Automatic Safety Belt Diagnosis, Indicator Short Test Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Panel Dimmer Switch Dimmer Switch: Locations Panel Dimmer Switch Behind LH Side Of I/P LH side of I/P, near LH front speaker Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations > Panel Dimmer Switch > Page 6134 Behind LH Side Of I/P Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6137 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6144 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6147 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6148 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6149 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6150 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6151 Dimmer Switch: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6152 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6153 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6154 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6155 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6156 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6157 Dimmer Switch: Electrical Diagrams Interior Lights Dimming Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6158 Interior Lights Dimming Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations In Respective Front Door Latch Assembly Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fuel Tank Unit And Lines (Typical) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6165 Fuel Pump/Fuel Gauge Sending Unit (typical) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6166 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit (typical) REMOVAL: 1. Before servicing the fuel pump the fuel system pressure must be relieved, see MAINTENANCE PROCEDURES. 2. Disconnect the negative battery cable. 3. Raise the car on a hoist. 4. Remove the fuel tank, 5. Remove the fuel tank sending unit and pump assembly by turning the cam lock ring counterclockwise. Lift assembly from the fuel tank. 6. Pull the fuel pump up into the attaching hose while pulling outward away from the bottom support. Take care to prevent damage to the rubber insulator and strainer during removal. After the pump assembly is clear of the bottom support, pull the pump assembly out of the rubber connector for removal. NOTE: Inspect the fuel pump attaching hose for any signs of deterioration. Also check the rubber sound insulator at the bottom of the pump. Replace damaged or deteriorated parts. INSTALLATION: 1. Push the fuel pump assembly into the attaching hose. 2. Position the fuel tank sending unit and pump assembly into the fuel tank. Use a new "O" ring seal. NOTE: Care should be taken not to fold over or twist the strainer when installing the sending unit as this will restrict the flow of fuel. Also, verify that the strainer does not block the full travel of the float arm. 3. Install cam lock over the assembly and lock by turning clockwise. 4. Reinstall fuel tank. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6167 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/T Shift Indicator Module: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned A/T Shift Indicator Module: All Technical Service Bulletins A/T - Shift Indicator Misaligned Number: 91-458-7A Section: 7A Date: DEC. 1991 Corporate Bulletin No.: 138305 ASE No.: A2 Subject: SHIFT INDICATOR MISALIGNED Model and Year: 1991 CAVALIER WITH AUTOMATIC TRANSMISSION Condition: Shift indicator may come out of adjustment. Cause: Adjuster did not "collapse" on indicator tape during production, thus creating a low ratcheting effort. Correction: Replace console trim plate with updated part. Refer to "Parts Information" for updated part number. Refer to Section 8C for replacement procedure. Parts Information: 22575236 Trim plate assembly - with power windows 22575237 Trim plate assembly - without power windows Parts are currently available from GMSPO. Warranty Information: Labor Operation Number: K5100 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > A/T Shift Indicator Module > Component Information > Technical Service Bulletins > Customer Interest for A/T Shift Indicator Module: > 914587A > Dec > 91 > A/T - Shift Indicator Misaligned A/T Shift Indicator Module: Customer Interest A/T - Shift Indicator Misaligned Number: 91-458-7A Section: 7A Date: DEC. 1991 Corporate Bulletin No.: 138305 ASE No.: A2 Subject: SHIFT INDICATOR MISALIGNED Model and Year: 1991 CAVALIER WITH AUTOMATIC TRANSMISSION Condition: Shift indicator may come out of adjustment. Cause: Adjuster did not "collapse" on indicator tape during production, thus creating a low ratcheting effort. Correction: Replace console trim plate with updated part. Refer to "Parts Information" for updated part number. Refer to Section 8C for replacement procedure. Parts Information: 22575236 Trim plate assembly - with power windows 22575237 Trim plate assembly - without power windows Parts are currently available from GMSPO. Warranty Information: Labor Operation Number: K5100 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Odometer/Speedometer - ACDelco Service Center Locations Speedometer Head: Technical Service Bulletins Odometer/Speedometer - ACDelco Service Center Locations File In Section: 8 - Chassis/Body Electrical Bulletin No.: 66-83-04A Date: September, 1996 INFORMATION Subject: AC Delco Service Center Locations for Odometer/Speedometer Service Models: 1997 and Prior Passenger Cars and Trucks (excluding Cadillac) This bulletin is being revised to provide the necessary contact information only. Please discard Corporate Bulletin Number 66-83-04 (Section 8 - Chassis/Body Electrical) General Motors provides service for sophisticated electronic products through the authorized AC Delco Service Center Program. This program is designed to provide GM vehicle owners with the highest quality and most technically up-to-date product available. Repair products from unauthorized service outlets are not acceptable as warranty replacements. Currently, there are 25 authorized AC Delco Service Centers who exchange and remanufacture odometer/speedometers (list included). Only these Centers should be contacted for service. Important: W series and 1997 T series Medium Duty truck odometer/speedometers must be ordered directly from GMSPO. The following steps should be taken when utilizing the AC Delco Service Centers: Dealers should contact their local AC Delco Service Center (list included). Any listed facility may be used. The following information must be provided: Part number VIN, Mileage, Vehicle Year, Make and Model Dealer Name and Address Delivery Date of Vehicle Name of the person requesting exchange or service Phone number Repair Order Number P.O. number (if non - warranty) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Odometer/Speedometer - ACDelco Service Center Locations > Page 6186 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Odometer/Speedometer - ACDelco Service Center Locations > Page 6187 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Odometer/Speedometer - ACDelco Service Center Locations > Page 6188 AC Delco Service Centers Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Page 6189 Speedometer Head: Testing and Inspection SPEEDOMETER IS INACCURATE (TEST A) 1. Connect a Scan Tool to the ALDL Connector. Drive the vehicle. Observe the Speedometer and compare it to the vehicle speed shown on the Scan Tool. - If both the Speedometer and Scan Tool display the same approximate speed, check for correct tire size, ECM MEM-CAL and Vehicle Speed Sensor. - If the Scan Tool and Speedometer do not display the same approximate speed, replace or exchange the Instrument Panel. ALTERNATE TEST - If the Kent Moore Tool J38522 is available, do the following test. 2. Connect a Scan Tool to the ALDL connector. Disconnect the Vehicle Speed Sensor connector. Connect a lead between the J38522 vehicle speed generator's red output terminal and the Vehicle Speed Sensor connector terminal A (YEL). Connect a lead between the J38522 generator's black output terminal B (PPL). Plug the generator into the Cigar Lighter. Select 30 V P-P sine wave and set the frequency at 600 hz. Observe the Speedometer and compare to the vehicle speed shown on the Scan Tool. - If both the Speedometer and Scan Tool display the same approximate speed, check for correct tire size, ECM MEM-CAL and Vehicle Speed Sensor. - If the Scan Tool and Speedometer do not display the same approximate speed, replace or exchange the Instrument Cluster. SPEEDOMETER/ODOMETER DON'T WORK (TEST B) Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Page 6190 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation This temperature indicating system consists of a sending unit, located on the cylinder head, electrical temperature gauge and an instrument voltage regulator. As engine temperature increases or decreases, the resistance of the sending unit changes, in turn controlling current flow through the gauge. When engine temperature is low sending unit resistance is high, current flow through the gauge is restricted, and the gauge pointer remains against the stop or moves very little. As engine temperature increases sending unit resistance decreases and current flow through the gauge increases, resulting in increased pointer movement. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Page 6194 Temperature Gauge: Testing and Inspection TEMPERATURE GAUGE INDICATES HOT 1. Disconnect coolant temperature sender connector. 2. Turn ignition switch ON. ^ If gauge indicates HOT, check for short in sender wire or printed circuit board. ^ If gauge indicates COLD, replace coolant temperature sender. TEMPERATURE GAUGE INDICATES COLD 1. Disconnect coolant temperature sender connector. 2. Ground coolant temperature sender wire. Turn ignition switch ON. ^ If gauge indicates COLD, check for open in sender wire or printed circuit board. ^ If gauge indicates HOT, replace coolant temperature sender. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Testing and Inspection Temperature Warning Lamp/Indicator: Testing and Inspection If the red light is not lit when the engine is being cranked, check for a burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when the engine is running, check the wiring between light and switch for a ground, temperature switch defective, or overheated cooling system. As a test circuit to check whether the red bulb is functioning properly, a wire which is connected to the ground terminal of the ignition switch is tapped into its circuit. When the ignition is in the start engine cranking position, the ground terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and the ignition switch is in the on position, the test circuit is opened and the bulb is then controlled by the temperature switch. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation Volt Meter Gauge: Description and Operation DELCOTRON CHARGING SYSTEM The CS generator uses a new type of regulator which has a built in fault detection. The CS generator does not have a diode trio or test hole. This generator uses only two connections, battery positive and an ``L'' terminal to the charge indicator bulb. Use of ``P,'' ``F'' and ``S'' terminals is optional. The ``P'' terminal is connected to the stator and may be connected to a tachometer or other device. The ``F'' terminal is connected internally to field positive and is used in service diagnostics. The ``S'' terminal may be connected externally to a voltage source, such as battery voltage. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Testing and Inspection > Alternator Indicator Lamp Volt Meter Gauge: Testing and Inspection Alternator Indicator Lamp DELCOTRON CHARGING If charge indicator light works abnormally, perform the following test procedure: 1. Visually check belt and wiring. 2. With engine control switch ON and engine stopped, charge indicator lamp should be on. If lamp is not on, detach wiring harness at generator and ground ``L'' terminal. If lamp lights, generator is faulty. If lamp does not light, locate open circuit between grounding lead and ignition switch and check for a faulty bulb. 3. With engine control switch ON and engine running at a moderate speed, charge indicator lamp should be off. If lamp is not off, detach wiring harness at generator. If lamp goes off, generator is faulty. If lamp stays on, check for grounded ``L'' terminal in wire harness. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Testing and Inspection > Alternator Indicator Lamp > Page 6207 Volt Meter Gauge: Testing and Inspection Voltmeter To check voltmeter, turn key and headlights on with engine off. Pointer should move to 12.5 volts. If no needle movement is observed, check connections from battery to circuit breaker. If connections are tight and meter shows no movement, check wire continuity. If wire continuity is satisfactory, the meter is inoperative and must be replaced. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations On Top LH Side Of Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission Backup Lamp Switch: Service and Repair Automatic Transmission On vehicles equipped with automatic transmission, the neutral start and back-up light switches are combined into one unit and must be replaced as an assembly. 1. Disconnect battery ground cable. 2. On 1989 Skyhawk and 1989-90 Cavalier models, remove console assembly as follows: a. Apply parking brake and block wheels, then place gear shift lever in Neutral position. b. Remove front ashtray, then remove two console attaching screws through ashtray opening. c. Carefully pry button from center of shift lever knob, then remove snap ring retaining knob. d. Pull front of console trim cover upward, then lift trim cover from console and disconnect wire connector. e. Remove three screws attaching front of console to mounting bracket. f. Remove rear ashtray, then remove screw attaching console to rear support. g. Remove console assembly. On models equipped with arm rest, it may be necessary to remove arm rest assembly to provide clearance for console removal. 3. On Sunbird models, remove console assembly as follows: a. Position gear selector in Neutral and block wheels. Do not apply parking brake. b. Carefully pry accessory trim panel, right and left side panels outward from console assembly. c. Remove console to instrument panel attaching nuts. d. Remove console assembly to console upper bracket attaching screws. e. Disconnect tape and disc player electrical connectors, then remove upper console bracket. f. Remove shift lever knob to shift lever attaching setscrew or retainer, then pry shift lever trim plate upward. g. Remove rear ashtray to console rear trim plate attaching screws, then remove rear ashtray. h. Remove console rear trim plate to console rear bracket attaching screw. i. On models equipped with armrest, remove armrest inner compartment attaching screw, then remove armrest to console rear bracket attaching screws, then remove armrest assembly. j. On all models, remove parking brake assembly and console from console mounting brackets. 4. On 1991-92 Cavalier models, remove console assembly as follows: a. Carefully pry accessory trim panel outward. b. Open ashtray, then remove attaching screw. c. Remove shift lever knob to shift lever attaching retainer. d. Disconnect cigar lighter electrical connector, then remove shifter trim plate. e. Remove upper and lower A/C-Heater control attaching screws. f. Disconnect radio electrical connector and antenna lead, then remove radio assembly. g. Disconnect A/C-Heater control electrical connectors and vacuum harness, then remove bowden cable to A/C-Heater control attaching screw, then remove A/C-Heater control assembly. h. Remove console to instrument panel attaching screws. i. Remove console rear storage compartment attaching screws. j. Disconnect remaining console electrical connectors, then remove console assembly. k. Remove console extension to front console bracket and shift control bracket attaching screws, then remove console extension. 5. On all models, disconnect wire connector from Neutral Safety/Back-up light switch. 6. Remove screws attaching switch to shifter lever, then remove switch. 7. If the same switch is to be reinstalled, proceed as follows: a. Place shift lever in Neutral position. b. Position switch to shift lever and loosely install attaching screws. c. Rotate switch on shifter to align adjustment hole with carrier tang, then insert a 3/32 inch maximum diameter pin into hole to a depth of 9/64 inch. d. On models, except 1991-92 Cavalier, torque switch attaching screws to 22 ft. lbs., then remove gauge pin. On 1991-92 Cavalier models, torque switch attaching screw to 18 ft. lbs., then remove gauge pin. 8. If a new replacement switch is to be installed, proceed as follows: a. Position shift lever in the Neutral position. b. Align shift shaft flats to switch flats. c. On models except 1991-92 Cavalier, torque switch attaching bolts to 22 ft. lbs. On 1991-92 Cavalier models, torque switch attaching bolts to 18 ft. lbs. If mounting bolts do not align with mounting holes ensure shift shaft is in Neutral position. Do not rotate switch. d. Ensure engine will only start in Park or Neutral. e. If engine will start in any other position place shift lever in Neutral position. f. Position switch to shift lever and loosen switch attaching screws. g. Rotate switch on shifter assembly to align service adjustment hole with carrier tang hole, then insert a 3/32 inch maximum diameter gauge pin into hole to a depth of 5/8 inch. h. Torque switch attaching screws to previous specified torque, then remove gauge pin. 9. Install console and connect battery ground cable. 10. Check to ensure that vehicle will not start in any shift lever position except Neutral and Park. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission > Page 6215 Backup Lamp Switch: Service and Repair Manual Transmission 1. Disconnect battery ground cable. 2. Disconnect back-up lamp switch electrical connector. 3. Remove back-up lamp switch from top of transaxle case. 4. Reverse procedure to install. Prior to installation, apply sealant 1052080 or equivalent to switch threads. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 6220 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6223 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6224 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6225 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6226 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6227 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6228 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6229 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6230 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6231 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6232 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6233 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6234 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6235 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6236 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6237 Brake Lamp: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6238 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6239 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6240 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6241 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6242 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6243 Exterior Lights: Stop-Turn Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Below LH Side Of I/P. Behind I/P, On Brake Pedal Support Applicable to: Cavalier w/Automatic Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6247 Brake Light Switch: Adjustments Insert stop lamp switch in retainer until switch body seats on retainer. Pull brake pedal upward against internal pedal stop. Switch will be moved in retainer providing proper adjustment. Proper switch adjustment is achieved when no audible clicks are heard when the pedal is pulled upward and the brake lights do not remain on without brake application. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6248 Brake Light Switch: Service and Repair 1. Disconnect battery ground cable. 2. On 1991-92 models, remove drivers' side hash panel. 3. On all models, disconnect switch electrical connector. 4. Remove switch from brake pedal support bracket. 5. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions Cargo Lamp: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6253 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6254 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6255 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6256 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6257 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6258 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6259 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6260 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6261 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6262 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6263 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6264 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6265 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6266 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6267 Cargo Lamp: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6268 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6269 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6270 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6271 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6272 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6273 Interior Lights: Cigarlighter/I/P Compartment/Luggage Compartment/Cargo Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations LH Front Corner Of Engine Compartment LH front corner of engine compartment Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Resistor > Component Information > Locations LH Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Technical Service Bulletins > IP Dimmer Control - Proper Setting Dimmer Switch: Technical Service Bulletins IP Dimmer Control - Proper Setting File In Section: 08 - Body and Accessories Bulletin No.: 99-08-42-009 Date: November, 1999 INFORMATION Subject: Proper Setting of I/P Dimmer Control to View PRNDL Display with Automatic Headlamp Control Models: 2000 and Prior All Passenger Cars and Trucks With Automatic Headlamp Control and Electronic PRNDL Display Under certain conditions, if the instrument panel dimmer control is turned relatively low, the PRNDL will not be visible until the automatic headlamp control turns the headlamps off and the daytime running lamps (DRL) are turned back on. Such a condition may be if the vehicle is first started in an environment where the headlamp control turns on the headlamps and then the vehicle is driven out into a brighter environment (for example, when a vehicle is backed out of a dark garage into the bright sunlight). This condition is normal and any repair attempt will not be successful. Demonstrate this condition to the customer using the service lane and then turn the instrument panel dimmer control to a higher setting. This will enable the driver to see the PRNDL display Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Panel Dimmer Switch Dimmer Switch: Locations Panel Dimmer Switch Behind LH Side Of I/P LH side of I/P, near LH front speaker Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Panel Dimmer Switch > Page 6287 Behind LH Side Of I/P Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6290 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6291 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6292 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6293 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6294 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6295 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6296 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6297 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6298 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6299 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6300 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6301 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6302 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6303 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6304 Dimmer Switch: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6305 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6306 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6307 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6308 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6309 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6310 Dimmer Switch: Electrical Diagrams Interior Lights Dimming Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6311 Interior Lights Dimming Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Technical Service Bulletins > Customer Interest for Dome Lamp: > 923318B > Nov > 92 > Lights - Dome & Reading Lamp Assembly Loose Dome Lamp: Customer Interest Lights - Dome & Reading Lamp Assembly Loose Number: 92-331-8B Section: 8B Date: NOV. 1992 Corporate Bulletin No.: 231067 ASE No.: A6 Subject: DOME AND READING LAMP ASSEMBLY LOOSE Model and Year: 1990-92 CAVALIER CONDITION Some owners of 1990-1992 Chevrolet "J" series vehicles with plastic dome and reading lamp assemblies may comment that the lamp assembly comes loose or falls from its attachment holes in the roof bow. CAUSE Base of lamp assembly bends slightly under high heat conditions or from excessive motion. Outside edge of each integral fastener then pulls away from metal of roof bow, resulting in poor retention of lamp assembly to roof bow. CORRECTION Replace current plastic dome and reading lamp assembly, GM P/N 22546379 with GM P/N 22585970 using the following procedure: Remove or Disconnect 1. Grasp front and rear of lamp assembly and pull downward while rocking lamp assembly back and forth to disengage integral fasteners from holes in roof bow. 2. Electrical connectors. Install or Connect 1. Electrical connector to new lamp assembly (GM P/N 22585970). 2. Position integral fasteners of lamp assembly to holes in roof bow and press lamp assembly into place. Inside edge of integral fastener contacts metal of roof bow to retain new lamp assembly. Parts are currently available from GMSPO. Labor Operation Number: N1456 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Dome Lamp: > 923318B > Nov > 92 > Lights - Dome & Reading Lamp Assembly Loose Dome Lamp: All Technical Service Bulletins Lights - Dome & Reading Lamp Assembly Loose Number: 92-331-8B Section: 8B Date: NOV. 1992 Corporate Bulletin No.: 231067 ASE No.: A6 Subject: DOME AND READING LAMP ASSEMBLY LOOSE Model and Year: 1990-92 CAVALIER CONDITION Some owners of 1990-1992 Chevrolet "J" series vehicles with plastic dome and reading lamp assemblies may comment that the lamp assembly comes loose or falls from its attachment holes in the roof bow. CAUSE Base of lamp assembly bends slightly under high heat conditions or from excessive motion. Outside edge of each integral fastener then pulls away from metal of roof bow, resulting in poor retention of lamp assembly to roof bow. CORRECTION Replace current plastic dome and reading lamp assembly, GM P/N 22546379 with GM P/N 22585970 using the following procedure: Remove or Disconnect 1. Grasp front and rear of lamp assembly and pull downward while rocking lamp assembly back and forth to disengage integral fasteners from holes in roof bow. 2. Electrical connectors. Install or Connect 1. Electrical connector to new lamp assembly (GM P/N 22585970). 2. Position integral fasteners of lamp assembly to holes in roof bow and press lamp assembly into place. Inside edge of integral fastener contacts metal of roof bow to retain new lamp assembly. Parts are currently available from GMSPO. Labor Operation Number: N1456 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions Dome Lamp: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6327 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6328 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6329 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6330 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6331 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6332 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6333 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6334 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6335 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6336 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6337 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6338 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6339 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6340 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6341 Dome Lamp: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6342 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6343 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6344 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6345 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6346 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6347 Dome Lamp: Electrical Diagrams Interior Lights: Illuminated Entry/Dome And Reading Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6348 Interior Lights: Illuminated Entry/Dome And Reading Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations In Respective Front Door Latch Assembly Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations The fuse panel is located on the left side of the instrument panel. To gain access to the panel, pivot access door downward. The hazard flasher is located under dash panel, left side of steering column. The turn signal flasher is located under dash panel, right side of steering column. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6366 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6369 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6370 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6371 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6372 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6373 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6374 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6375 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6376 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6377 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6378 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6379 Headlamp Switch: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6380 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6381 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6382 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6383 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6384 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6385 Headlamp Switch: Electrical Diagrams Light Switch Details Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6386 Light Switch Details Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6387 Light Switch Details Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay To Convenience Center Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Locations > Lamp Dimmer Module I/P Harness To Turns Signal Flasher & Lamp Dimmer Module Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Lamp Control Module > Component Information > Locations > Lamp Dimmer Module > Page 6396 Behind LH Side Of I/P Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6404 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6405 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6406 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6407 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6408 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6409 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6410 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6411 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6412 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6413 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6414 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6415 License Plate Lamp: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6416 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6417 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6418 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6419 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6420 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6421 License Plate Lamp: Electrical Diagrams Exterior Lights: Tail/Rear Marker/License Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6422 Exterior Lights: Tail/Rear Marker/License Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6423 Exterior Lights: Tail/Rear Marker/License Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Technical Service Bulletins > Customer Interest for Map Light: > 923318B > Nov > 92 > Lights - Dome & Reading Lamp Assembly Loose Map Light: Customer Interest Lights - Dome & Reading Lamp Assembly Loose Number: 92-331-8B Section: 8B Date: NOV. 1992 Corporate Bulletin No.: 231067 ASE No.: A6 Subject: DOME AND READING LAMP ASSEMBLY LOOSE Model and Year: 1990-92 CAVALIER CONDITION Some owners of 1990-1992 Chevrolet "J" series vehicles with plastic dome and reading lamp assemblies may comment that the lamp assembly comes loose or falls from its attachment holes in the roof bow. CAUSE Base of lamp assembly bends slightly under high heat conditions or from excessive motion. Outside edge of each integral fastener then pulls away from metal of roof bow, resulting in poor retention of lamp assembly to roof bow. CORRECTION Replace current plastic dome and reading lamp assembly, GM P/N 22546379 with GM P/N 22585970 using the following procedure: Remove or Disconnect 1. Grasp front and rear of lamp assembly and pull downward while rocking lamp assembly back and forth to disengage integral fasteners from holes in roof bow. 2. Electrical connectors. Install or Connect 1. Electrical connector to new lamp assembly (GM P/N 22585970). 2. Position integral fasteners of lamp assembly to holes in roof bow and press lamp assembly into place. Inside edge of integral fastener contacts metal of roof bow to retain new lamp assembly. Parts are currently available from GMSPO. Labor Operation Number: N1456 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Map Light: > 923318B > Nov > 92 > Lights - Dome & Reading Lamp Assembly Loose Map Light: All Technical Service Bulletins Lights - Dome & Reading Lamp Assembly Loose Number: 92-331-8B Section: 8B Date: NOV. 1992 Corporate Bulletin No.: 231067 ASE No.: A6 Subject: DOME AND READING LAMP ASSEMBLY LOOSE Model and Year: 1990-92 CAVALIER CONDITION Some owners of 1990-1992 Chevrolet "J" series vehicles with plastic dome and reading lamp assemblies may comment that the lamp assembly comes loose or falls from its attachment holes in the roof bow. CAUSE Base of lamp assembly bends slightly under high heat conditions or from excessive motion. Outside edge of each integral fastener then pulls away from metal of roof bow, resulting in poor retention of lamp assembly to roof bow. CORRECTION Replace current plastic dome and reading lamp assembly, GM P/N 22546379 with GM P/N 22585970 using the following procedure: Remove or Disconnect 1. Grasp front and rear of lamp assembly and pull downward while rocking lamp assembly back and forth to disengage integral fasteners from holes in roof bow. 2. Electrical connectors. Install or Connect 1. Electrical connector to new lamp assembly (GM P/N 22585970). 2. Position integral fasteners of lamp assembly to holes in roof bow and press lamp assembly into place. Inside edge of integral fastener contacts metal of roof bow to retain new lamp assembly. Parts are currently available from GMSPO. Labor Operation Number: N1456 Use applicable labor time guide for labor hours. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions Map Light: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6439 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6440 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6441 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6442 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6443 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6444 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6445 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6446 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6447 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6448 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6449 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6450 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6451 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6452 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6453 Map Light: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6454 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6455 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6456 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 Map Light: Electrical Diagrams Interior Lights: Illuminated Entry/Dome And Reading Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 Interior Lights: Illuminated Entry/Dome And Reading Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6465 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6466 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6467 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6468 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6469 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6470 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6471 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6472 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6473 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6474 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6475 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6476 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6477 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6478 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6479 Marker Lamp: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6480 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6481 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6482 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6483 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6484 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6485 Marker Lamp: Electrical Diagrams Exterior Lights: Hazard/Front Marker/Front Park/Turn Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6486 Exterior Lights: Tail/Rear Marker/License Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6487 Exterior Lights: Tail/Rear Marker/License Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6488 Exterior Lights: Tail/Rear Marker/License Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 6493 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6496 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6497 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6498 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6499 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6500 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6501 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6502 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6503 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6504 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6505 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6506 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6507 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6508 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6509 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6510 Parking Lamp: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6511 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6512 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6513 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6514 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6515 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6516 Exterior Lights: Hazard/Front Marker/Front Park/Turn Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations LH Front Corner Of Engine Compartment LH front corner of engine compartment Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay To Convenience Center Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Locations > Lamp Dimmer Module I/P Harness To Turns Signal Flasher & Lamp Dimmer Module Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Locations > Lamp Dimmer Module > Page 6528 Behind LH Side Of I/P Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations On Top LH Side Of Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission Backup Lamp Switch: Service and Repair Automatic Transmission On vehicles equipped with automatic transmission, the neutral start and back-up light switches are combined into one unit and must be replaced as an assembly. 1. Disconnect battery ground cable. 2. On 1989 Skyhawk and 1989-90 Cavalier models, remove console assembly as follows: a. Apply parking brake and block wheels, then place gear shift lever in Neutral position. b. Remove front ashtray, then remove two console attaching screws through ashtray opening. c. Carefully pry button from center of shift lever knob, then remove snap ring retaining knob. d. Pull front of console trim cover upward, then lift trim cover from console and disconnect wire connector. e. Remove three screws attaching front of console to mounting bracket. f. Remove rear ashtray, then remove screw attaching console to rear support. g. Remove console assembly. On models equipped with arm rest, it may be necessary to remove arm rest assembly to provide clearance for console removal. 3. On Sunbird models, remove console assembly as follows: a. Position gear selector in Neutral and block wheels. Do not apply parking brake. b. Carefully pry accessory trim panel, right and left side panels outward from console assembly. c. Remove console to instrument panel attaching nuts. d. Remove console assembly to console upper bracket attaching screws. e. Disconnect tape and disc player electrical connectors, then remove upper console bracket. f. Remove shift lever knob to shift lever attaching setscrew or retainer, then pry shift lever trim plate upward. g. Remove rear ashtray to console rear trim plate attaching screws, then remove rear ashtray. h. Remove console rear trim plate to console rear bracket attaching screw. i. On models equipped with armrest, remove armrest inner compartment attaching screw, then remove armrest to console rear bracket attaching screws, then remove armrest assembly. j. On all models, remove parking brake assembly and console from console mounting brackets. 4. On 1991-92 Cavalier models, remove console assembly as follows: a. Carefully pry accessory trim panel outward. b. Open ashtray, then remove attaching screw. c. Remove shift lever knob to shift lever attaching retainer. d. Disconnect cigar lighter electrical connector, then remove shifter trim plate. e. Remove upper and lower A/C-Heater control attaching screws. f. Disconnect radio electrical connector and antenna lead, then remove radio assembly. g. Disconnect A/C-Heater control electrical connectors and vacuum harness, then remove bowden cable to A/C-Heater control attaching screw, then remove A/C-Heater control assembly. h. Remove console to instrument panel attaching screws. i. Remove console rear storage compartment attaching screws. j. Disconnect remaining console electrical connectors, then remove console assembly. k. Remove console extension to front console bracket and shift control bracket attaching screws, then remove console extension. 5. On all models, disconnect wire connector from Neutral Safety/Back-up light switch. 6. Remove screws attaching switch to shifter lever, then remove switch. 7. If the same switch is to be reinstalled, proceed as follows: a. Place shift lever in Neutral position. b. Position switch to shift lever and loosely install attaching screws. c. Rotate switch on shifter to align adjustment hole with carrier tang, then insert a 3/32 inch maximum diameter pin into hole to a depth of 9/64 inch. d. On models, except 1991-92 Cavalier, torque switch attaching screws to 22 ft. lbs., then remove gauge pin. On 1991-92 Cavalier models, torque switch attaching screw to 18 ft. lbs., then remove gauge pin. 8. If a new replacement switch is to be installed, proceed as follows: a. Position shift lever in the Neutral position. b. Align shift shaft flats to switch flats. c. On models except 1991-92 Cavalier, torque switch attaching bolts to 22 ft. lbs. On 1991-92 Cavalier models, torque switch attaching bolts to 18 ft. lbs. If mounting bolts do not align with mounting holes ensure shift shaft is in Neutral position. Do not rotate switch. d. Ensure engine will only start in Park or Neutral. e. If engine will start in any other position place shift lever in Neutral position. f. Position switch to shift lever and loosen switch attaching screws. g. Rotate switch on shifter assembly to align service adjustment hole with carrier tang hole, then insert a 3/32 inch maximum diameter gauge pin into hole to a depth of 5/8 inch. h. Torque switch attaching screws to previous specified torque, then remove gauge pin. 9. Install console and connect battery ground cable. 10. Check to ensure that vehicle will not start in any shift lever position except Neutral and Park. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission > Page 6535 Backup Lamp Switch: Service and Repair Manual Transmission 1. Disconnect battery ground cable. 2. Disconnect back-up lamp switch electrical connector. 3. Remove back-up lamp switch from top of transaxle case. 4. Reverse procedure to install. Prior to installation, apply sealant 1052080 or equivalent to switch threads. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Below LH Side Of I/P. Behind I/P, On Brake Pedal Support Applicable to: Cavalier w/Automatic Transaxle Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6539 Brake Light Switch: Adjustments Insert stop lamp switch in retainer until switch body seats on retainer. Pull brake pedal upward against internal pedal stop. Switch will be moved in retainer providing proper adjustment. Proper switch adjustment is achieved when no audible clicks are heard when the pedal is pulled upward and the brake lights do not remain on without brake application. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6540 Brake Light Switch: Service and Repair 1. Disconnect battery ground cable. 2. On 1991-92 models, remove drivers' side hash panel. 3. On all models, disconnect switch electrical connector. 4. Remove switch from brake pedal support bracket. 5. Reverse procedure to install. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations In Respective Front Door Latch Assembly Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6548 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6549 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6550 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6551 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6552 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6553 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6554 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6555 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6556 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6557 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6558 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6559 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6560 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6561 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6562 Headlamp Switch: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6563 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6564 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6565 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6566 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6567 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6568 Headlamp Switch: Electrical Diagrams Light Switch Details Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6569 Light Switch Details Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6570 Light Switch Details Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > Turn Signal Switch - Correct Cancellation After R&R; Turn Signal Switch: Technical Service Bulletins Turn Signal Switch - Correct Cancellation After R&R; Number: 93-181-3F Section: 3F Date: MAY 1993 Corporate Bulletin No.: 333204 ASE No.: A4 Subject: INFORMATIONAL PROCEDURE TO INSURE CORRECT TURN SIGNAL SWITCH CANCELLATION WHEN INSTALLING NEW SWITCH Model and Year: 1991-93 CAVALIER SERVICE UPDATE When replacing an inoperative turn signal switch, pay attention to the tightening sequence of the mounting bolts. It is important to torque the upper bolt first, and secondly the lower bolt. Both bolts should be tightened to 3-5 N-m (27-44 lbs. in.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 6579 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6582 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6583 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6584 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6585 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6586 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6587 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6588 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6589 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6590 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6591 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6592 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6593 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6594 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6595 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6596 Tail Lamp: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6597 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6598 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6599 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6600 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6601 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6602 Tail Lamp: Electrical Diagrams Exterior Lights: Tail/Rear Marker/License Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6603 Exterior Lights: Tail/Rear Marker/License Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6604 Exterior Lights: Tail/Rear Marker/License Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions Trunk Lamp: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6609 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6610 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6611 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6612 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6613 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6614 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6615 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6616 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6617 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6618 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6619 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6620 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6621 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6622 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6623 Trunk Lamp: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6624 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6625 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6626 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6627 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6628 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6629 Interior Lights: Cigarlighter/I/P Compartment/Luggage Compartment/Cargo Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations The fuse panel is located on the left side of the instrument panel. To gain access to the panel, pivot access door downward. The hazard flasher is located under dash panel, left side of steering column. The turn signal flasher is located under dash panel, right side of steering column. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Turn Signal 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 6638 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Technical Service Bulletins > Turn Signal Switch - Correct Cancellation After R&R; Turn Signal Switch: Technical Service Bulletins Turn Signal Switch - Correct Cancellation After R&R; Number: 93-181-3F Section: 3F Date: MAY 1993 Corporate Bulletin No.: 333204 ASE No.: A4 Subject: INFORMATIONAL PROCEDURE TO INSURE CORRECT TURN SIGNAL SWITCH CANCELLATION WHEN INSTALLING NEW SWITCH Model and Year: 1991-93 CAVALIER SERVICE UPDATE When replacing an inoperative turn signal switch, pay attention to the tightening sequence of the mounting bolts. It is important to torque the upper bolt first, and secondly the lower bolt. Both bolts should be tightened to 3-5 N-m (27-44 lbs. in.). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Cell References CELL REFERENCES General Motors vehicles often use "CELL" references in their electrical wiring diagrams. These references are used in the Original Equipment Manual to refer to a section in the manual and not a specific diagram(s). GM Sample Diagram W/ Cell Reference For instance, in the diagram illustrated "Cell 20" is not a reference to another diagram but a reference to "Section 20" in the OE manual. In the example, "Section 20" is the engine control section of the manual. To navigate through these "Cell" references start at the vehicle level and go to: Diagrams / Electrical Diagrams - for a complete list of the diagrams available for the vehicle. Choose the system you are working on and view those diagrams. Note: If unsure of the system - try utilizing the search feature. Type a component in the search feature that belongs to the system and when the results are displayed note the path displayed. This will show the system the component belongs in. Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6648 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6649 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6650 Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6651 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6652 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6653 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6654 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6655 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6656 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6657 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6658 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6659 Schematic Symbols Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6660 Schematic Symbols Wire Color Code Identification WIRE COLOR ABBREVIATION BLACK BLK BLUE BLU DARK BLUE DK BLU LIGHT BLUE LT BLU BROWN BRN GRAY GRY Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6661 GREEN GRN DARK GREEN DK GRN LIGHT GREEN LT GRN ORANGE ORN PINK PNK PURPLE PPL RED RED TAN TAN WHITE WHT YELLOW YEL Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6662 Heated Glass Element: Diagnostic Aids Pull-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent. Figure 20 - Typical Pull-To-Seat Connector Follow the steps below to repair Pull-To-Seat connectors (Figure 20). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply. 1. Separate connector halves. Using the proper pick or removal tool, remove terminal (see Figures 21 & 22). a. Pull lead gently. b. Insert pick from front of connector into canal. c. Pry tab up with tool. d. Push lead to remove. Figure 21 Figure 22 2. If terminal is to be re-used, re-form locking tang. 3. Make repair. a. Pull terminal wire out of connector body. b. Cut wire as close to terminal as possible. c. Strip 5 mm (3/16") of insulation from the wire (see Figure 23). d. Crimp new terminal to wire. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6663 e. Solder with rosin core solder. f. Carefully pull on wire to draw terminal into connector body until it locks. Push-to-Seat Connectors NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J38125 or equivalent. Figure 1 - Typical Push-To-Seat Connector Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors Do Not require all the steps shown. Skip the steps that Do Not apply. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. 1. Separate connector halves (see Figures 2 through 6). Figure 2 Figure 3 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6664 Figure 4 Figure 5 Figure 6 2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11). Figure 7 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6665 Figure 8 Figure 9 Figure 10 Figure 11 3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16). Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6666 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 4. Make repair. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6667 When using a new terminal: a. Slip cable seal away from terminal (if seal exist). b. Cut wire as close to terminal as possible. c. Slip a new cable seal onto wire (if necessary). d. Strip 5mm (3/16") of insulation from wire. e. Crimp a new terminal to the wire. f. Solder with rosin core solder. g. Slide cable seal toward terminal (if equipped with a seal). h. Crimp cable seal and insulation (if equipped with a seal). i. Apply grease to connectors outside the passenger compartment where the connector originally was equipped with grease. Figure 17 To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice. 5. Insert lead from the back until it catches. 6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19). Figure 18 Figure 19 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 6668 Rear Defogger Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations Power Window Motor: Locations Near Lower Front Of Respective Door Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Back 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 (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Door 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 6686 Front Door Window Glass: Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box 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 add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 6687 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter Windshield: Customer Interest Body - Stain/Film On Windshield Glass Perimeter TECHNICAL Bulletin No.: 09-08-48-006 Date: September 18, 2009 Subject: Clear Stain or Film on Inside Perimeter of Windshield Glass (Clean/Polish Glass) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Condition Some customers may comment on a clear stain or film on the inside of the windshield glass. This condition appears along the outer edges of the glass along the top, bottom or A-pillar areas. Normal glass cleaning procedures will not remove the stain. Cause The assembly plant uses a clear sealer/primer on the outer edge of the windshield glass to improve adhesion to the urethane adhesive that bonds the windshield glass to the vehicle body. Excess sealer/primer may drip or flow onto the windshield and cause a stain. Once the sealer/primer dries, it may appear to have etched the glass. Correction Note A "white" type of toothpaste is recommended for this repair. Gel-type toothpaste may provide less satisfactory results. Use a small amount of toothpaste on a soft, cotton cloth to polish the stained area. It may be necessary to wrap the cloth around a paint stir stick or a similar tool to reach the lower corners of the windshield glass. After polishing the glass, clean the inside of the windshield glass with a clean, damp, cotton cloth and verify all of the stain is removed. Do not use any cleaners or solvents - use only clean warm water. 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. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter > Page 6700 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-48-002A > Mar > 09 > Body - Marks/Stains on Windshield When Wet Windshield: Customer Interest Body - Marks/Stains on Windshield When Wet TECHNICAL Bulletin No.: 09-08-48-002A Date: March 19, 2009 Subject: Marks/Stains on Windshield When Wet (Clean Windshield) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-48-002 (Section 08 - Body and Accessories). Condition Some owners may comment that marks/stains appear on the windshield when the windshield is wet. Cause This condition may be caused by contact between the windshield and the vacuum hoses or other tools used in the assembly process. This contact may leave a residue that creates a water repellent surface on the glass which, in wet conditions, appear as marks/stains on the surface. Correction Important DO NOT REPLACE THE WINDSHIELD FOR THIS CONDITION. To clean the windshield, use Eastwood Glass Polishing Compound*. Follow the manufacturer's directions for product use. Use only hand tools. DO NOT USE POWER TOOLS. Parts Information Eastwood Glass Polishing Compound 1-800-343-9353 (for overseas inquiries: +1-610-705-2200) http://www.eastwoodco.com/ *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 the table above. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance Windshield: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance > Page 6710 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Windshield: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter Windshield: All Technical Service Bulletins Body - Stain/Film On Windshield Glass Perimeter TECHNICAL Bulletin No.: 09-08-48-006 Date: September 18, 2009 Subject: Clear Stain or Film on Inside Perimeter of Windshield Glass (Clean/Polish Glass) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Condition Some customers may comment on a clear stain or film on the inside of the windshield glass. This condition appears along the outer edges of the glass along the top, bottom or A-pillar areas. Normal glass cleaning procedures will not remove the stain. Cause The assembly plant uses a clear sealer/primer on the outer edge of the windshield glass to improve adhesion to the urethane adhesive that bonds the windshield glass to the vehicle body. Excess sealer/primer may drip or flow onto the windshield and cause a stain. Once the sealer/primer dries, it may appear to have etched the glass. Correction Note A "white" type of toothpaste is recommended for this repair. Gel-type toothpaste may provide less satisfactory results. Use a small amount of toothpaste on a soft, cotton cloth to polish the stained area. It may be necessary to wrap the cloth around a paint stir stick or a similar tool to reach the lower corners of the windshield glass. After polishing the glass, clean the inside of the windshield glass with a clean, damp, cotton cloth and verify all of the stain is removed. Do not use any cleaners or solvents - use only clean warm water. 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. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter > Page 6719 Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-48-002A > Mar > 09 > Body - Marks/Stains on Windshield When Wet Windshield: All Technical Service Bulletins Body - Marks/Stains on Windshield When Wet TECHNICAL Bulletin No.: 09-08-48-002A Date: March 19, 2009 Subject: Marks/Stains on Windshield When Wet (Clean Windshield) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-48-002 (Section 08 - Body and Accessories). Condition Some owners may comment that marks/stains appear on the windshield when the windshield is wet. Cause This condition may be caused by contact between the windshield and the vacuum hoses or other tools used in the assembly process. This contact may leave a residue that creates a water repellent surface on the glass which, in wet conditions, appear as marks/stains on the surface. Correction Important DO NOT REPLACE THE WINDSHIELD FOR THIS CONDITION. To clean the windshield, use Eastwood Glass Polishing Compound*. Follow the manufacturer's directions for product use. Use only hand tools. DO NOT USE POWER TOOLS. Parts Information Eastwood Glass Polishing Compound 1-800-343-9353 (for overseas inquiries: +1-610-705-2200) http://www.eastwoodco.com/ *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 the table above. Disclaimer Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 83-15-16 > Oct > 98 > New Windshield/Glass Urethane Adhesive Caulking Kit Windshield: All Technical Service Bulletins New Windshield/Glass Urethane Adhesive Caulking Kit File In Section: 10 - Body Bulletin No.: 83-15-16 Date: October, 1998 INFORMATION Subject: New Windshield and Stationary Glass Urethane Adhesive Caulking Kit Models: 1990-99 All Passenger Cars and Trucks As a result of a change from standard viscosity urethane to high-viscosity urethane, a new Urethane Adhesive Caulking Kit, P/N 12346392, is now available from GMSPO. This kit contains the "High Viscosity" Urethane Adhesive for thicker and more consistent bead size applications. When applied properly, this new high viscosity urethane in many instances will eliminate the need for depth setting blocks or the damming material to control squeeze out. The following is the contents of the new kit: Like the standard viscosity urethane contained in kit (P/N 12346284) that it replaces, it is a one-part, moisture cure product with curing times that vary as a result of changes in either temperature or humidity. THE REQUIRED TIME FOR THIS NEW ONE-PART MATERIAL to ensure a safe installation of stationary glass before returning the vehicle to the customer, IS A MINIMUM OF SIX (6) HOURS AT 70°F (21°C) AND 30% RELATIVE HUMIDITY. Alternate equivalent materials for this kit may be available from a local glass repair shop under the following product numbers: Other manufacturers of Urethane Adhesive that have documented their ability to meet or exceed General Motors specification # 3651M (Performance Requirements for Stationary Glass Bonding Adhesive System Service) are also considered to be equivalent to GM Kit (P/N 12346392). In previously published Corporate Bulletin Number 73-10-54, increasing customer demands for faster service have resulted in quicker two-part urethane adhesives to be made available. Essex Beta Seal U216* (two-part urethane adhesive) also meets the General Motors 3651M Specification and can be Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 83-15-16 > Oct > 98 > New Windshield/Glass Urethane Adhesive Caulking Kit > Page 6728 used when the customer demands quicker repair of the vehicle than the above described one-part product can provide. This two-part, chemical cure product requires ONE (1) TO ONE-AND-ONE-HALF (1-1/2) HOURS FOR CURING BEFORE RETURNING THE VEHICLE TO THE CUSTOMER. This two-part product also requires primers on the glass and pinchweld surfaces. The primers and applicator daubers are not included with this two-part product and therefore, must be purchased separately. In addition, this two-part product requires a special applicator (gun) for proper mixing and dispensing of the adhesive. Important: The U216 product is NOT available from GMSPO and must be obtained locally. * 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 products which may be available from other sources. When using either of the above described products, make sure to follow the manufacturer's directions for application and drying times. For information regarding the removal and installation of stationary glass, consult the appropriate Service Manual. Parts information P/N Description 12346392 Urethane Adhesive Caulking Kit Parts are expected to be available from GMSPO, 10/12/98. Important: The previously recommended adhesive kit (P/N 12346284) will no longer be available from GMSPO once inventory is exhausted. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 72-05-04 > Aug > 97 > Warranty - Guidelines for Claiming Windshield Replace Windshield: All Technical Service Bulletins Warranty - Guidelines for Claiming Windshield Replace File In Section: Warranty Administration Bulletin No.: 72-05-04 Date: August, 1997 WARRANTY ADMINISTRATION Subject: Guidelines for Claiming C0034 - Windshield Replacement Models: 1989-98 Passenger Cars and Light Duty Trucks The purpose of this bulletin is to provide retail and wholesale service personnel with guidelines for using the above subject labor operations. In an effort to understand the windshield replacements, the following two phase approval process is being implemented. We feel this approach will allow GM to be responsive to repair decisions on vehicles over 10,000 miles (16,000KMS), while providing you, our dealers, the empowerment to address customer needs on those cases requiring repairs early in the vehicle's life, under 10,000 miles (16,000KMS). Effective with repair orders dated on or after September 1, 1997, dealers are to be guided by the following: ^ Windshield replacement on vehicles under 10,000 miles (16,0OOKMS) can only be made after Service Management inspection, review and approval. This approval must be noted on the repair order clearly identifying the defect and reason for replacement. This comment must be submitted in the comment field of the claim for engineering review. ^ Windshield replacement on vehicles over 10,000 miles (16,000KMS) can only be made after Service Management inspection, review and approval from the divisional service representative. Vehicles may be required to be held for wholesale inspection. This approval must be noted on the repair order clearly identifying the defect and reason for replacement. This comment must be submitted in the comment field of the claim for engineering review. The claim will require wholesale authorization for payment. Additional Requirements ^ Windshields replaced must be held for the normal parts retention period and the defect should be clearly identified on the glass by means of tape and/or a grease pencil. ^ Sublet windshield replacements, like other sublet repairs are to be claimed for actual dealership cost less any discounts and or allowances offered. Sublet repairs cannot exceed the normal allowance provided to the dealership had the repair been completed in-house. See your GM Policy and Procedure Manual for the complete guidelines. Windshields damaged by normal wear, road hazards, vandalism, or other physical damage are not eligible for warranty coverage. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 73-10-54 > May > 97 > Windshield - Two-Part Urethane Adhesive For Installation Windshield: All Technical Service Bulletins Windshield - Two-Part Urethane Adhesive For Installation File In Section: 10 - Body Bulletin No.: 73-10-54 Date: May, 1997 INFORMATION Subject: Two-Part Urethane Adhesive For Windshield Installations Models: 1997 And Prior Passenger Cars and Trucks (Using Urethane Adhesive To Retain Windshields) General Motors passenger cars and trucks use urethane adhesive as a means to retain the windshield in the body opening. The urethane adhesive is used to bond the windshield in the opening, increasing vehicle structure. The current recommended urethane adhesive, GM P/N 12346284, is a one-part moisture cure product that requires a minimum curing period of 6 hours at room temperature before returning the vehicle to the customer. Increasing customer demands for faster service in recent years have resulted in quicker cure two-part urethane adhesives. Essex Beta Seal U216* (two-part urethane adhesive) meets the General Motors 3651M Specification (Performance Requirements for Stationary Glass Bonding Adhesive System Service) and can be used when the customer demands quicker repair of the vehicle than the current one-part materials can provide. Either of these products can be used when glass replacement is performed. The differences between these products are as follows: The CURRENT URETHANE ADHESIVE KIT, GM P/N 12346284, IS A ONE-PART ADHESIVE. It includes the necessary glass and pinchweld primers and is specified in Service Manuals for General Motors' vehicles. Since this is a "moisture cure" product, the curing time for this one-part material will vary with changes to either temperature or humidity. The REQUIRED TIME FOR THIS ONE-PART MATERIAL to ensure a safe installation of stationary glass before returning the vehicle to the customer IS A MINIMUM OF SIX (6) HOURS AT 70°F (21°C) AND 30% RELATIVE HUMIDITY. ESSEX BETA SEAL U216 IS A TWO-PART ADHESIVE MATERIAL THAT PROVIDES FOR A ONE (1) TO ONE AND ONE HALF (11/2) HOUR CURE BEFORE RETURNING THE VEHICLE TO THE CUSTOMER. This product also requires primers on the glass and pinchweld surfaces. This product requires a special applicator for the mixing and dispensing of the adhesive. When using this (or any) product, make sure to follow the manufacturer's directions for application and drying times. Parts Information Parts are currently available from GMSPO. * We believe this source and their product 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 products which may be available from other sources. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 911268E > Nov > 90 > Wiper Blades - Chattering on Windshield Windshield: All Technical Service Bulletins Wiper Blades - Chattering on Windshield Number: 91-126-8E Section: 8E Date: November 1990 Corporate Bulletin No.: 031066 Subject: CHATTERING WIPER BLADES OR BLADE WIPEABILITY Model and Year: ALL PASSENGER CARS AND TRUCKS TO: ALL CHEVROLET DEALERS Condition: Chattering and poor wipeability comments may be due to the windshield glass and/or wiper blades becoming contaminated by insect residue, dirt, road grime, carwax etc. Correction: 1. Clean the windshield glass with GM # 1050011 (Bon Ami) glass cleaner or equivalent. Important: The glass is clean when rinse water does not "bead-up," but "sheets" across the entire glass surface. Multiple cleanings may be required to remove all contaminants. 2. Clean the wiper blades by using a cloth that has been saturated with full strength washer solution and wipe vigorously. Rinse the blades with water after cleaning. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance Wiper Blade: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance > Page 6746 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 923448E > Feb > 93 > Wipers - Blade Chatter/Wipeability Wiper Blade: All Technical Service Bulletins Wipers - Blade Chatter/Wipeability Number: 92-344-8E Section: 8E Date: FEB. 1993 Corporate Bulletin No.: 078308R ASE No.: B1 Subject: WINDSHIELD WIPER BLADE CHATTER/WIPEABILITY CONCERNS Model and Year: 1982-92 "J" SERIES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-195-8E, DATED FEB. 1991. THE WIPER BLADE HAS BEEN REVISED AND THE 1992 MODEL YEAR HAS BEEN ADDED. ALL COPIES OF 91-195-8E SHOULD BE DISCARDED. CONDITION: Some 1982-92 "J" vehicles may experience wiper blade chatter and wipeability concerns. IMPORTANT: Before replacing any part, clean windshield with GM windshield cleaner, P/N 1050011 or equivalent. The glass is clean when rinse water does not "bead-up" across entire glass surface. Multiple cleanings may be required to remove all contaminants. Also, clean the wiper blades by using a cloth that has been saturated with full strength washer solution by wiping vigorously. CORRECTION: A revised, all metal wiper blade with six pressure points is available which may correct most wipeability concerns. This design replaces the four pressure point design as shown in Figure 2. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 923448E > Feb > 93 > Wipers - Blade Chatter/Wipeability > Page 6751 Replace both blades with P/N 22110234. Use appropriate labor operation and time. Coupes and Convertibles only: If conditions persist, follow the procedure below. Install spacer package, P/N 22111290, over driver side linkage housing as shown in Figure 1. Make sure spacer is correctly oriented. Install new screws provided and torque evenly to 8 N-m (70 lbs.in.). NOTE: When reassembling cowl, make sure that washer hose is reconnected (and not pinched). If an interference condition results between the wiper arm head casting and the cowl clearance hole, use a file to enlarge hole at interference point. This procedure should not be used for 1993 vehicles, as a revised arm has been introduced which incorporates a revised blade angle. Parts are currently available from GMSPO. WARRANTY INFORMATION Labor Operation Number: T4677 Labor Time: 0.4 hour Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 91358A8E > Apr > 92 > Windshield Wiper Blades - Chatter Wiper Blade: All Technical Service Bulletins Windshield Wiper Blades - Chatter Number: 91-358A-8E Section: 8E Date: APRIL 1992 Coporate Bulletin No.: 131029R ASE No.: B1 Subject: WINDSHIELD WIPER BLADE CHATTER Model and Year: 1988-91 CAVALIER THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN 91-358-8E, DATED JUNE 1991. THE VEHICLE IDENTIFICATION NUMBERS (VIN) HAVE BEEN CORRECTED. ALL COPIES OF 91-358-8E SHOULD BE DISCARDED. IMPORTANT: Before replacing any part, clean windshield and both blades with GM windshield cleaner, P/N 1050011 or equivalent. The glass is clean when rinse water does not "bead-up" across entire glass surface. Multiple cleaning may be required to remove all contaminants. Also, clean the wiper blades by using a cloth that has been saturated with full strength washer solution and wiping vigorously. Rinse the blades with clean water after cleaning. Condition: Some 1988-1991 "J" cars built prior to the VIN Breakpoints listed below may exhibit windshield wiper chatter or reduced wipeability at road speeds. A revised graphite impregnated wiper blade insert was used in production to improve wiper performance. VIN BREAKPOINTS Chevrolet MJ180300 M7153762 Pontiac M7566731 Correction: Install revised insert. Carefully inspect blade assembly for bent or damaged conditions. Install revised wiper blade assembly if any damage is found. P/N 22121047 Insert Wiper Blade P/N 5049926 Blade, Assembly With Insert Parts are currently available from GMSPO. Labor Operation Number: T1746 Labor Time: 0.3 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 911268E > Nov > 90 > Wiper Blades - Chattering on Windshield Wiper Blade: All Technical Service Bulletins Wiper Blades - Chattering on Windshield Number: 91-126-8E Section: 8E Date: November 1990 Corporate Bulletin No.: 031066 Subject: CHATTERING WIPER BLADES OR BLADE WIPEABILITY Model and Year: ALL PASSENGER CARS AND TRUCKS TO: ALL CHEVROLET DEALERS Condition: Chattering and poor wipeability comments may be due to the windshield glass and/or wiper blades becoming contaminated by insect residue, dirt, road grime, carwax etc. Correction: 1. Clean the windshield glass with GM # 1050011 (Bon Ami) glass cleaner or equivalent. Important: The glass is clean when rinse water does not "bead-up," but "sheets" across the entire glass surface. Multiple cleanings may be required to remove all contaminants. 2. Clean the wiper blades by using a cloth that has been saturated with full strength washer solution and wipe vigorously. Rinse the blades with water after cleaning. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 923448E > Feb > 93 > Wipers - Blade Chatter/Wipeability > Page 6765 Replace both blades with P/N 22110234. Use appropriate labor operation and time. Coupes and Convertibles only: If conditions persist, follow the procedure below. Install spacer package, P/N 22111290, over driver side linkage housing as shown in Figure 1. Make sure spacer is correctly oriented. Install new screws provided and torque evenly to 8 N-m (70 lbs.in.). NOTE: When reassembling cowl, make sure that washer hose is reconnected (and not pinched). If an interference condition results between the wiper arm head casting and the cowl clearance hole, use a file to enlarge hole at interference point. This procedure should not be used for 1993 vehicles, as a revised arm has been introduced which incorporates a revised blade angle. Parts are currently available from GMSPO. WARRANTY INFORMATION Labor Operation Number: T4677 Labor Time: 0.4 hour Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations Windshield Washer Control Module: Locations Behind LH Side Of I/P, Strapped To RH Side Of Steering Column Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection Multi Function Lever Test Wiper Washer Switch Voltage Chart PROCEDURE Disconnect wiring harnesses from wiper motor and perform the following multi-function lever tests using a digital voltmeter with ignition switch on. All voltage readings taken with respect to vehicle ground. Probe terminals 1 through 4 with digital voltmeter and multi-function lever in various positions. If the Multi-Function Lever Test is not completed correctly, then the multi-Function lever is defective. However, it is possible that the wiring harness is defective and has an open or short. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation Washer Fluid Level Indicator: Description and Operation There are two types of low washer fluid indicating systems. They are the mechanical type and electrically controlled type. The mechanical type consists of a float and rod assembly, sending unit and a fiber optic. The electrically controlled type consists of a float, magnet, contact points and a resistor. On the mechanical type, the upper end of the rod extends into the sending unit and has colored red and green portions. When the windshield wipers are activated, a lamp bulb in the sending unit lights either the red or green sections of the rod. The colored light is then picked up by the fiber optic and is transmitted through it to the telltale lens. The lens will show red or green depending upon washer fluid level. The electrically controlled indicator is activated when the windshield wipers are engaged. A slight amount of current flows from the wiper motor to the washer bottle float unit. This current will either pass through the contact points or the resistor which is in parallel with the points. When the washer fluid level is high, the magnet holds the contact points open. The current will now flow through the resistor where it is reduced so the indicator will not light. When the washer fluid level is low, the float drops and the magnet will separate from the cap assembly allowing the current to pass through the contact points and activate the indicator light. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation > Page 6782 Washer Fluid Level Indicator: Testing and Inspection On the mechanical indicating system, if the telltale lens fails to glow when the windshield wipers are activated, check lamp bulb in sending unit and see that fiber optic is not broken. On the electrically controlled system, the first item to check is the indicator bulb. With the windshield wipers On, connect a jumper wire between the two terminals on the washer bottle cap. The indicator should then light. If not, replace bulb. If the bulb is found to be satisfactory, remove cap and float assembly from washer bottle. Float should be able to move to the bottom of the stem and the magnet should separate from the cap. If not, replace float and cap assembly. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations Windshield Washer Control Module: Locations Behind LH Side Of I/P, Strapped To RH Side Of Steering Column Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Windshield Washer Pump: Locations Near LH Strut Tower, In Washer Fluid Reservoir Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 6789 Windshield Washer Pump: Testing and Inspection Washer Pump On Vehicle Check PROCEDURE Check for washer pump operation before removing from vehicle. Remove connector and apply B(+) to # 2 wiring harness terminal. 1. If motor does not run or pump water, replace washer pump. 2. If motor runs and pumps water, problem is in circuit board, motor park switch or wiper switch, refer to Wiper Switch / Testing and Inspection. See: Sensors and Switches - Wiper and Washer Systems/Wiper Switch/Testing and Inspection Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest: > 91358A8E > Apr > 92 > Windshield Wiper Blades - Chatter Wiper Blade: Customer Interest Windshield Wiper Blades - Chatter Number: 91-358A-8E Section: 8E Date: APRIL 1992 Coporate Bulletin No.: 131029R ASE No.: B1 Subject: WINDSHIELD WIPER BLADE CHATTER Model and Year: 1988-91 CAVALIER THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN 91-358-8E, DATED JUNE 1991. THE VEHICLE IDENTIFICATION NUMBERS (VIN) HAVE BEEN CORRECTED. ALL COPIES OF 91-358-8E SHOULD BE DISCARDED. IMPORTANT: Before replacing any part, clean windshield and both blades with GM windshield cleaner, P/N 1050011 or equivalent. The glass is clean when rinse water does not "bead-up" across entire glass surface. Multiple cleaning may be required to remove all contaminants. Also, clean the wiper blades by using a cloth that has been saturated with full strength washer solution and wiping vigorously. Rinse the blades with clean water after cleaning. Condition: Some 1988-1991 "J" cars built prior to the VIN Breakpoints listed below may exhibit windshield wiper chatter or reduced wipeability at road speeds. A revised graphite impregnated wiper blade insert was used in production to improve wiper performance. VIN BREAKPOINTS Chevrolet MJ180300 M7153762 Pontiac M7566731 Correction: Install revised insert. Carefully inspect blade assembly for bent or damaged conditions. Install revised wiper blade assembly if any damage is found. P/N 22121047 Insert Wiper Blade P/N 5049926 Blade, Assembly With Insert Parts are currently available from GMSPO. Labor Operation Number: T1746 Labor Time: 0.3 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance Wiper Blade: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance > Page 6803 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 923448E > Feb > 93 > Wipers - Blade Chatter/Wipeability Wiper Blade: All Technical Service Bulletins Wipers - Blade Chatter/Wipeability Number: 92-344-8E Section: 8E Date: FEB. 1993 Corporate Bulletin No.: 078308R ASE No.: B1 Subject: WINDSHIELD WIPER BLADE CHATTER/WIPEABILITY CONCERNS Model and Year: 1982-92 "J" SERIES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-195-8E, DATED FEB. 1991. THE WIPER BLADE HAS BEEN REVISED AND THE 1992 MODEL YEAR HAS BEEN ADDED. ALL COPIES OF 91-195-8E SHOULD BE DISCARDED. CONDITION: Some 1982-92 "J" vehicles may experience wiper blade chatter and wipeability concerns. IMPORTANT: Before replacing any part, clean windshield with GM windshield cleaner, P/N 1050011 or equivalent. The glass is clean when rinse water does not "bead-up" across entire glass surface. Multiple cleanings may be required to remove all contaminants. Also, clean the wiper blades by using a cloth that has been saturated with full strength washer solution by wiping vigorously. CORRECTION: A revised, all metal wiper blade with six pressure points is available which may correct most wipeability concerns. This design replaces the four pressure point design as shown in Figure 2. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 923448E > Feb > 93 > Wipers - Blade Chatter/Wipeability > Page 6808 Replace both blades with P/N 22110234. Use appropriate labor operation and time. Coupes and Convertibles only: If conditions persist, follow the procedure below. Install spacer package, P/N 22111290, over driver side linkage housing as shown in Figure 1. Make sure spacer is correctly oriented. Install new screws provided and torque evenly to 8 N-m (70 lbs.in.). NOTE: When reassembling cowl, make sure that washer hose is reconnected (and not pinched). If an interference condition results between the wiper arm head casting and the cowl clearance hole, use a file to enlarge hole at interference point. This procedure should not be used for 1993 vehicles, as a revised arm has been introduced which incorporates a revised blade angle. Parts are currently available from GMSPO. WARRANTY INFORMATION Labor Operation Number: T4677 Labor Time: 0.4 hour Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 91358A8E > Apr > 92 > Windshield Wiper Blades - Chatter Wiper Blade: All Technical Service Bulletins Windshield Wiper Blades - Chatter Number: 91-358A-8E Section: 8E Date: APRIL 1992 Coporate Bulletin No.: 131029R ASE No.: B1 Subject: WINDSHIELD WIPER BLADE CHATTER Model and Year: 1988-91 CAVALIER THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN 91-358-8E, DATED JUNE 1991. THE VEHICLE IDENTIFICATION NUMBERS (VIN) HAVE BEEN CORRECTED. ALL COPIES OF 91-358-8E SHOULD BE DISCARDED. IMPORTANT: Before replacing any part, clean windshield and both blades with GM windshield cleaner, P/N 1050011 or equivalent. The glass is clean when rinse water does not "bead-up" across entire glass surface. Multiple cleaning may be required to remove all contaminants. Also, clean the wiper blades by using a cloth that has been saturated with full strength washer solution and wiping vigorously. Rinse the blades with clean water after cleaning. Condition: Some 1988-1991 "J" cars built prior to the VIN Breakpoints listed below may exhibit windshield wiper chatter or reduced wipeability at road speeds. A revised graphite impregnated wiper blade insert was used in production to improve wiper performance. VIN BREAKPOINTS Chevrolet MJ180300 M7153762 Pontiac M7566731 Correction: Install revised insert. Carefully inspect blade assembly for bent or damaged conditions. Install revised wiper blade assembly if any damage is found. P/N 22121047 Insert Wiper Blade P/N 5049926 Blade, Assembly With Insert Parts are currently available from GMSPO. Labor Operation Number: T1746 Labor Time: 0.3 Hours Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 911268E > Nov > 90 > Wiper Blades - Chattering on Windshield Wiper Blade: All Technical Service Bulletins Wiper Blades - Chattering on Windshield Number: 91-126-8E Section: 8E Date: November 1990 Corporate Bulletin No.: 031066 Subject: CHATTERING WIPER BLADES OR BLADE WIPEABILITY Model and Year: ALL PASSENGER CARS AND TRUCKS TO: ALL CHEVROLET DEALERS Condition: Chattering and poor wipeability comments may be due to the windshield glass and/or wiper blades becoming contaminated by insect residue, dirt, road grime, carwax etc. Correction: 1. Clean the windshield glass with GM # 1050011 (Bon Ami) glass cleaner or equivalent. Important: The glass is clean when rinse water does not "bead-up," but "sheets" across the entire glass surface. Multiple cleanings may be required to remove all contaminants. 2. Clean the wiper blades by using a cloth that has been saturated with full strength washer solution and wipe vigorously. Rinse the blades with water after cleaning. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Blade: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance Wiper Blade: All 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Blade: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance > Page 6822 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 (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Blade: > 923448E > Feb > 93 > Wipers - Blade Chatter/Wipeability Wiper Blade: All Technical Service Bulletins Wipers - Blade Chatter/Wipeability Number: 92-344-8E Section: 8E Date: FEB. 1993 Corporate Bulletin No.: 078308R ASE No.: B1 Subject: WINDSHIELD WIPER BLADE CHATTER/WIPEABILITY CONCERNS Model and Year: 1982-92 "J" SERIES THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-195-8E, DATED FEB. 1991. THE WIPER BLADE HAS BEEN REVISED AND THE 1992 MODEL YEAR HAS BEEN ADDED. ALL COPIES OF 91-195-8E SHOULD BE DISCARDED. CONDITION: Some 1982-92 "J" vehicles may experience wiper blade chatter and wipeability concerns. IMPORTANT: Before replacing any part, clean windshield with GM windshield cleaner, P/N 1050011 or equivalent. The glass is clean when rinse water does not "bead-up" across entire glass surface. Multiple cleanings may be required to remove all contaminants. Also, clean the wiper blades by using a cloth that has been saturated with full strength washer solution by wiping vigorously. CORRECTION: A revised, all metal wiper blade with six pressure points is available which may correct most wipeability concerns. This design replaces the four pressure point design as shown in Figure 2. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Blade: > 923448E > Feb > 93 > Wipers - Blade Chatter/Wipeability > Page 6827 Replace both blades with P/N 22110234. Use appropriate labor operation and time. Coupes and Convertibles only: If conditions persist, follow the procedure below. Install spacer package, P/N 22111290, over driver side linkage housing as shown in Figure 1. Make sure spacer is correctly oriented. Install new screws provided and torque evenly to 8 N-m (70 lbs.in.). NOTE: When reassembling cowl, make sure that washer hose is reconnected (and not pinched). If an interference condition results between the wiper arm head casting and the cowl clearance hole, use a file to enlarge hole at interference point. This procedure should not be used for 1993 vehicles, as a revised arm has been introduced which incorporates a revised blade angle. Parts are currently available from GMSPO. WARRANTY INFORMATION Labor Operation Number: T4677 Labor Time: 0.4 hour Trouble Code: 92 Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Blade: > 911268E > Nov > 90 > Wiper Blades - Chattering on Windshield Wiper Blade: All Technical Service Bulletins Wiper Blades - Chattering on Windshield Number: 91-126-8E Section: 8E Date: November 1990 Corporate Bulletin No.: 031066 Subject: CHATTERING WIPER BLADES OR BLADE WIPEABILITY Model and Year: ALL PASSENGER CARS AND TRUCKS TO: ALL CHEVROLET DEALERS Condition: Chattering and poor wipeability comments may be due to the windshield glass and/or wiper blades becoming contaminated by insect residue, dirt, road grime, carwax etc. Correction: 1. Clean the windshield glass with GM # 1050011 (Bon Ami) glass cleaner or equivalent. Important: The glass is clean when rinse water does not "bead-up," but "sheets" across the entire glass surface. Multiple cleanings may be required to remove all contaminants. 2. Clean the wiper blades by using a cloth that has been saturated with full strength washer solution and wipe vigorously. Rinse the blades with water after cleaning. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair Wiper Gear Box: Service and Repair 1. Remove wiper arms from transmission spindle shafts. 2. Remove shroud top vent grille panel and screen. 3. Loosen, but do not remove, transmission drive link to motor crank arm attaching nuts then pull drive link from motor crank arm. 4. Remove transmission to cowl panel attaching screws and the transmission assembly. 5. Reverse procedure to install. Torque wiper transmission attaching screws and nuts to 64 inch lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations Wiper Motor: Locations Front Of Dash. Center Front Of Dash Applicable to: 1991 Cavalier Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 6838 Wiper Motor: Description and Operation Pulse Wiper Motor MOTOR DESCRIPTION The pulse windshield wiper is a permanent magnet positive park pulse wiper. The pulse and demand wash functions are controlled by a plug-in printed circuit board enclosed in the wiper's die-cast aluminum housing cover. Internal parts of the wiper motor assembly, field magnet, armature, drive gear, park switch actuator and brush holder assembly are enclosed in an aluminum die-cast housing with a plastic cover. The housing and cover are attached to each other by seven rivets. A radio frequency interference suppressor is located in the terminal connector on the wiper motor. A strap attached to one of the motor bolt hole grommets provides a ground for the suppressor. An automatic reset type circuit breaker located on the motor brush holder assembly protects the motor. A fuse in the fuse block protects the vehicle wiring. There are four terminals which are lettered for illustrative purposes. The function of each terminal is covered in the explanation that follows. Use care when disconnecting the lock-type connectors that attach vehicle wiring to the wiper. The wiper motor has three brushes: common, low speed and high speed. When the ignition switch is ON, a (+) 12V circuit is applied to both the low and high speed fixed contacts in the multi-function lever. The low and high speed brushes are connected to the multi-function lever through terminals C and D. The armature is grounded through the common brush via the ground strap. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Wiper Motor Bench Test Bench Testing Wiper Motor Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Wiper Motor Bench Test > Page 6841 Wiper Motor: Testing and Inspection Wiper Motor Test Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Wiper Motor Bench Test > Page 6842 Wiper Motor On Vehicle Check PROCEDURE Check for motor operation before removing from vehicle. Disconnect all wiring from wiper and perform the 5 mode checks (6 with pulse) in the image. 1. If wiper motor functions in all modes, go to Wiper Switch / Testing and Inspection. See: Sensors and Switches - Wiper and Washer Systems/Wiper Switch/Testing and Inspection 2. If the motor does not function in any one of the mode checks, refer to Wiper and Washer Systems / Testing and Inspection. See: Testing and Inspection Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Page 6843 Wiper Motor: Service and Repair 1. Disconnect battery ground cable. 2. Remove wiper arms from transmission spindle shafts. 3. Remove shroud top vent grille panel and screen. 4. Loosen, but do not remove, transmission drive link to motor crank arm attaching nuts, then pull drive link out of motor crank arm. 5. Disconnect wiper motor electrical connections and remove wiper motor attaching bolts. 6. Rotate wiper motor upward and outward, and remove from vehicle. 7. Reverse procedure to install. Torque wiper motor attaching bolts to 48 inch lbs. Chevrolet Cavalier Workshop Manual (Cavalier-Z24 L4-134 2.2L (1991)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection Multi Function Lever Test Wiper Washer Switch Voltage Chart PROCEDURE Disconnect wiring harnesses from wiper motor and perform the following multi-function lever tests using a digital voltmeter with ignition switch on. All voltage readings taken with respect to vehicle ground. Probe terminals 1 through 4 with digital voltmeter and multi-function lever in various positions. If the Multi-Function Lever Test is not completed correctly, then the multi-Function lever is defective. However, it is possible that the wiring harness is defective and has an open or short.