Chevrolet TrailBlazer - Service Manual

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Essential Notes before Proceeding2
Safety Notice2
Part Numbers2
Special Tools2
Precautions3
Servicing Your Vehicle Safely4
Do's4
Don'ts5
Product View6
Engine Electrical7
Service Precautions7
Ignition System9
General Information9
Coil on Plug (COP) System9
Magnetic Sensor / Pick-Up Coil9
Ignition Coil10
Related Symptoms10
Secondary Spark Test11
Firing Orders14
Ignition Coil-On-Plug14
Removal & Installation14
4.2L Engine14
5.3L & 6.0L Engines15
Charging System17
Generator18
Voltage Test18
Load Test18
No-Load Test18
Generator Removal and Installation (4.2L Engine)19
Generator Removal and Installation (5.3L & 6.0L Engines)20
Generator Battery Control Module: Removal & Installation22
200722
Maintenance Intervals23
But the Owner's Manual Is Different?23
But the Replacement Part Is Different?24
Is My Driving 'Normal' or 'Severe'?24
Typical Underhood Maintenance Locations for Inline-Type Engines25
Typical Underhood Maintenance Locations for V or Opposing-Type Engines25
Typical Body and Undervehicle Maintenance Locations26
Typical Lubrications, from Left to Right: Engine Oil; Gear Oil; ATF; Wheel Bearing Grease; Brake Fluid; Chassis Grease; White Grease; and Silicone Spr27
Special Tools Make Lubrication Easier, from Left to Right: Oil Suction Gun; Oil Can; Funnel; Grease Gun; and Wheel Bearing Packers28
Underhood Maintenance Intervals29
Body and Undervehicle Maintenance Intervals30
Recommended Lubricants31
Hall-Effect Device35
Starting System36
Battery: Removal & Installation36
Starter37
Testing37
Starting System Voltage Drop Tests37
Starter Feed Circuit37
Starter Solenoid38
Removal & Installation: 4.2L Engine39
Removal & Installation: 5.3L & 6.0L Engines40
Starter Relay: Removal & Installation42
Engine Repair43
Precautions43
Cleanliness and Care, Shop Practice44
Engine Mechanical45
Camshaft: Removal & Installation (4.2L Engine)46
J 44222 Installation46
Camshaft Cap Removal and Installation47
Camshaft Removal and Installation48
Camshaft Sensor Removal and Installation49
Camshaft: Removal & Installation (5.3L & 6.0L Engines)49
Camshaft Sprocket Removal and Installation50
Camshaft Retainer Removal and Installation50
Crankshaft Balancer53
Crankshaft Balancer Installer54
Crankshaft Balancer Removal55
Cylinder Head: Removal & Installation (4.2L Engine)57
EN-48464 Installation58
Cylinder Head Bolt Removal and Installation59
Cylinder Head Removal and Installation60
Cylinder Head Bolt Tightening Sequence61
5.3L & 6.0L Engines: Left Side64
Left Cylinder Head Removal and Installation64
Right Side66
Right Cylinder Head Removal and Installation66
Drive Belt Removal and Installation (4.2L Engine)68
Drive Belt Removal and Installation (5.3L & 6.0L Engines)70
Drive Belt Tensioner Removal and Installation (4.2L Engine)72
Accessory Drive Belt Tensioner (5.3L, 6.0L)73
Drive Belt Tensioner Removal and Installation (5.3L & 6.0L Engines)73
Engine Assembly: Removal & Installation (4.2L Engine)74
Heater Core Hoses75
Powertrain Control Module (PCM) Removal and Installation76
Starter77
Engine Grounds78
Transmission Removal and Installation79
Rear of the Engine82
Engine Assembly: Removal & Installation (5.3L & 6.0L Engines)82
Engine Coolant Temperature Sensor (ECT) Connector83
Engine Grounds84
Lift Bracket Removal and Installation85
Transmission Bolts and Studs Removal and Installation86
Flywheel Removal and Installation (4.2L Engine)89
Flywheel Bolt Tightening Sequence90
Flywheel Removal and Installation (5.3L & 6.0L Engines)91
Drivebelt Idler Pulley Removal and Installation (4.2L Engine)93
Drivebelt Idler Pulley Removal and Installation (5.3L Engine)94
Idler Pulley94
Intake Manifold: Removal & Installation (4.2L Engine)96
Powertrain Control Module (PCM) Removal and Installation96
Intake Manifold Removal and Installation97
Intake Manifold: Removal & Installation (5.3L & 6.0L Engines)99
Intake Manifold Bolt Tightening Sequence102
Oil Pan102
Oil Pan Removal and Installation (4.2L Engine)103
Oil Pan Removal and Installation (5.3L & 6.0L Engines)104
Oil Pan Removal and Installation105
Oil Pump: Removal & Installation (4.2L Engine)107
Oil Pump Cover107
Oil Pump: Removal & Installation (5.3L & 6.0L Engines)108
Crankshaft Rear Oil Seal: Removal & Installation (4.2L Engine)110
Crankshaft Rear Oil Seal: Removal & Installation (5.3L & 6.0L Engines)111
Camshaft Cover Removal and Installation (4.2L Engine)112
Valve Rocker Arm Cover: Removal & Installation (5.3L & 6.0L Engines)114
Valve Rocker Arm & Valve Lash Adjuster: Removal & Installation (4.2L Engine)117
EN-47945 Valve Spring Compressor117
Valve Rocker Arm & Valve Lash Adjuster: Removal & Installation (5.3L & 6.0 Engines)118
Valve Rocker Arm Pivot Support119
Engine Front Cover: Removal & Installation (4.2L Engine)120
Engine Front Cover Center Bolt (A)120
Engine Front Cover Sealer Application121
Engine Front Cover Removal and Installation (3L & 6.0L Engines)123
Camshaft Timing Chain, Sprocket, and Tensioner: Removal & Installation (4.2L Engine)125
Exhaust Camshaft Position Actuator Removal125
Intake Camshaft Sprocket Removal126
Timing Chain Tensioner Removal and Installation126
J 44221 Camshaft Holding Tool127
Timing Chain Alignment128
Timing Chain & Sprocket: Removal & Installation (5.3L Engine)130
Crankshaft Sprocket Removal and Installation130
Timing Chain Tensioner Removal and Installation131
Crankshaft Sprocket Removal131
Crankshaft Sprocket Installation132
Engine Cooling133
Coolant Reservoir: Removal & Installation133
Coolant134
Filling & Bleeding134
Cooling Fan & Shroud: Removal & Installation135
Fan Clutch Removal and Installation135
Radiator Removal and Installation136
Engine Coolant Thermostat: Removal & Installation (4.2L Engine)138
Engine Coolant Thermostat: Removal & Installation (5.3L & 6.0L Engines)139
Water Pump: Removal & Installation (4.2L Engine)140
Water Pump Pulley Removal and Installation140
Water Pump: Removal & Installation (5.3L & 6.0L Engines)142
Auxiliary Heater Inlet and Outlet Hose/Pipe Removal and Installation142
Water Pump Removal and Installation143
Engine Exhaust144
Exhaust Manifold: Removal & Installation (4.2L Engine)144
Exhaust Manifold Bolt Tightening Sequence145
Left Exhaust Manifold Removal and Installation (5.3L & 6.0L Engines)146
Right Exhaust Manifold Removal and Installation147
Catalytic Converter: Removal & Installation (4.2L Engine)149
Muffler Removal and Installation149
Catalytic Converter: Removal & Installation (5.3L & 6.0L Engines)150
Engine Reconditioning152
Determining Engine Condition152
Compression Test153
Screw-In Type Compression Gauge153
Oil Pressure Test154
Overhaul Tips155
Cleaning155
Scraping Head Gasket155
Ring Groove Cleaner Tool156
Cleaning Groove with an Old Ring157
Repairing Damaged Threads158
Standard Thread Repair Insert (Left), and Spark Plug Thread Insert158
Disassembly162
OHV Heads162
Valve Spring Compressor Tool162
A Small Magnet Used in Removal of Valve Locks162
Valve Locks (Keepers)163
O-Ring Type Seal163
Umbrella/Positive Type Seal164
Removing Exhaust Valve164
OHC Cylinder Heads165
Exploded View of a Valve, Seal, Spring, Retainer and Locks from an OHC Cylinder Head165
Example of a Multi-Valve Cylinder Head with 2 Intake and 2 Exhaust Valve Ports165
Cup Type Camshaft Followers166
C-Clamp Type Spring Compressor and an OHC Spring Removal Tool (Center) for Cup Type Followers166
Cup Type Bolt-On Bearing Caps166
Rocker Arm Type Camshaft Followers167
OHC Spring Tool and C-Clamp167
OHC Shaft Mounted Rocker Arms168
OHC Rocker Arm Type Head168
Compressing the Valve Spring170
Removing the Valve Rocks170
Valve Spring and Retainer171
Removing Valve Seal from the Gauge171
Valve Spring Shim172
Inspection173
Valves173
Springs, Retainers & Valve Locks174
Spring Free-Length Check175
Valve Spring Squareness Check175
Valve Guides176
Valve Seats176
Reading Stem-To-Guide Clearance176
Cylinder Head Surface Flatness177
Machinist's Straight Edge and Feeler Gauge177
Diagonal Check177
Camshaft & Followers178
Refinishing & Repairing178
Cracks & Physical Damage178
Lapping the Valves179
Valve Guide179
Cylinder Head Surface181
Cracks and Physical Damage181
Assembly182
OHV Engines182
OHC Engines182
Cup Type Camshaft Followers182
Rocker Arm Type Camshaft Followers183
Engine Block184
Disassembly184
Pushrod Engines184
All Engines184
Cylinder Ridge Removal186
Crankshaft Bearing Alignment186
Deck Flatness186
Cylinder Bores186
Measuring Cylinder Bore Diameter187
Crankshaft188
Piston & Connecting Rods188
Pressed-On Pistons188
Connecting Rod189
Measuring the Piston's Outed Diameter189
Bearings190
Oil Pump190
Refinishing191
Pistons & Connecting Rods191
Ball Type Cylinder Hone191
Front of Piston Mark192
Assembly193
Crankshaft193
Checking Bearing Clearance with Gauging Material193
Measuring Bearing Clearance Gauging Material194
Measuring Crankshaft End-Play195
Pistons, Rings & Connecting Rods196
Checking Ring Groove Clearance196
Bearing Cap Notch197
Ring Top Side Marks198
Piston and Rod Assembly Installation198
Camshaft, Lifters & Timing Assembly199
Cylinder Head(S)199
Engine Covers & Components199
Engine Start-Up & Break-In200
Starting the Engine200
Drivability & Emissions Controls201
Precautions201
Cleanliness and Care, Shop Practice202
Emissions Controls System Overview203
Emission Control System204
Carbon Monoxide (CO)205
Hydrocarbon (HC)205
Oxides of Nitrogen (NO)205
Photochemical Smog205
Sulfur Oxides (Sox)206
Air Pollution206
Natural Pollutants206
Industrial Pollutants206
Automotive Pollutants207
Temperature Inversion207
Heat Transfer208
Automative Emissions209
Exhaust Gases209
Hydrocarbons209
Carbon Monoxide210
Nitrogen210
Ozone210
Oxides of Sulfur211
Particulate Matter211
Crankcase Emissions212
Evaporative Emissions212
Electronic Engine Controls214
MAP Sensor214
FTP Sensor214
Canister Purge Valve Only Vehicles214
Vehicles with Canister Purge and Vent Valves215
ECT Sensor215
APP Sensor215
CKP Sensor216
CMP Sensor216
Typical Crankshaft Position (CKP) Sensor216
Ho2S217
Typical CMP Sensor217
IAT Sensor218
Typical Oxygen Sensor218
Knock Sensor219
MAF Sensor219
TP Sensor219
VSS Sensor220
Typical TP Sensor220
Typical VSS221
Evaporative Emission Canister: Removal & Installation222
Evaporative Emission Canister Purge Solenoid Valve: Removal & Installation (4.2L Engine)224
Evaporative Emission Canister Purge Solenoid Valve: Removal & Installation (5.3L & 6.0L Engines)225
Evaporative Emission Canister Vent Solenoid Valve: Removal & Installation227
Fuel Tank Pressure Sensor: Removal & Installation228
Positive Crankcase Ventilation Hoses: Removal & Installation229
Mass Airflow/Intake Air Temperature Sensor: Removal & Installation230
Arrow )A), Mass Airflow/Intake Air Temperature Sensor232
Camshaft Position Sensor: Removal & Installation (4.2L Engine)233
Camshaft Position Sensor (5.3L Engine)234
2003-2004234
Camshaft Position Sensor Removal and Installation (5.3L & 6.0L Engines)235
2005-2007235
Engine Coolant Temperature Sensor: Removal & Installation (4.2L Engine)237
Engine Coolant Temperature Sensor Removal and Installation (5.3L & 6.0L Engines)238
Crankshaft Position Sensor: Removal & Installation (4.2L Engine)239
Crankshaft Position Sensor: Removal & Installation (5.3L & 6.0L Engines)240
Powertrain Control Module (PCM): Removal & Installation (4.2L Engine)241
2002-2005241
2006-2007242
Powertrain Control Module (PCM) Removal and Installation (5.3L & 6.0L Engines)243
2003 - 2004243
Powertrain Control Module (PCM)244
Engine Control Module (ECM): Removal & Installation (5.3L & 6.0L Engines)245
2005 - 2007245
Engine Control Module (ECM)246
Knock Sensor (KS): Removal & Installation (4.2L Engine)247
Knock Sensor (KS) Removal and Installation (5.3L Engine)248
Knock Sensor (KS) 1 Removal and Installation (5.3L & 6.0L Engines)249
Knock Sensor (KS) 2 Removal and Installation250
Manifold Absolute Pressure (MAP) Sensor: Removal & Installation (4.2L Engine)251
Manifold Absolute Pressure (MAP) Sensor Removal and Installation (5.3L Engine)252
Oil Pressure Switch: Removal & Installation (4.2L Engine)253
Oil Pressure Sensor253
Oil Pressure Sensor: Removal & Installation (5.3L & 6.0L Engines)254
Heated Oxygen Sensor: Removal & Installation (4.2L Engine)255
Sensor 1255
Sensor 2256
Heated Oxygen Sensors Removal and Installation (5.3L & 6.0L Engines)257
Accelerator Pedal Position Sensor: Removal & Installation258
Vehicle Speed Sensor: Removal & Installation259
Vehicle Speed Sensor (A), Retaining Bolt (B), O-Ring (C)259
Trouble Codes260
Scan Tools260
Generic Codes261
DTC Description261
Fuel System302
Service Precautions302
Fuel Injection303
Fuel Lines and Fittings: Removal & Installation304
Quick Connect Fitting (S) Service (Metal Cover)304
Quick Connect Retainer304
J 37088-A Fuel Line Disconnect Tool304
Quick Connect Fitting (S) Service (Plastic Collar)305
Types of Plastic Quick Connect Fittings305
Bartholomew306
Q Release306
Sliding Retainer307
Fuel Injectors308
Testing308
All Injectors Clicking308
One or more Injectors Are Not Clicking309
Fuel Injector Balance Test311
Preliminary Checks311
Injector Balance Test Procedure311
Injector Balance Test Analysis311
Fuel Injector Removal and Installation (4.2L Engine)312
Fuel Injector (A), Part Number (B), Build Date Code (C), Month (D), Day (E), Year (F), Shift (G)313
Fuel Injector Removal and Installations (5.3L & 6.0L Engines)314
Fuel Rail Assembly: Removal & Installation (4.2L Engine)316
Fuel Rail Assembly: Removal & Installation (5.3L & 6.0L Engines)317
Fuel Filter: Removal & Installation320
2002 - 2004320
Fuel Pressure Regulation: Removal & Installation (4.2L Engine)322
5.3L Engine322
Fuel Sender Assembly: Removal & Installation324
Fuel System Pressure326
Relieving Fuel System Pressure326
Fuel System Circuit Showing the Pressure Test Port on the Supply Rail (Typical)326
Fuel System Pressure Test327
Fuel Tank: Removal & Installation328
Evaporative Emission Canister Pipes Removal and Installation328
Fuel Tank Removal and Installation329
Throttle Bosy: Removal & Installation (4.2L Engine)333
Throttle Body Removal and Installation (2002-2004)334
Chassis Electrical336
Supplemental Inflatable Restraint (SIR) System Service Precautions337
Basic Electricity338
Basic Electrical Theory338
Voltage338
Amperage338
How Does Electricity Work: the Water Analogy341
Ohm's Law342
Electrical Components343
Power Source343
The Battery343
The Alternator343
Protective Devices344
Fuse Panel Inside Driver's Side Kick Panel344
Switches & Relays345
Underhood Fuse and Relay Panel345
Load346
Wiring & Harnesses347
Connectors348
Weatherproof Connector348
Test Equipment349
Jumper Wires349
Hard Shell (Left) and Weatherproof (Right) Connectors349
Test Lights350
12 Volt Test Light350
Multimeters351
Basic Troubleshooting353
Testing354
Open Circuits354
Short Circuits354
Open Circuit Measurement354
Voltage Drop355
Low Voltage Measurement355
Resistance356
Coolant Temperature Sensor Resistance356
Spark Plug Wire Resistance357
Air Bag (Supplemental Restraint System)358
Battery Cables358
Disconnecting the Cables358
Disarming & Arming359
Air Bag Fuse359
Negative Battery Cable359
Circuit Protection359
Underhood Fuse Block (4.2L Engine) (2002-2005 Early Production)360
Except Saab360
Underhood Fuse Block (2003 - 2005 Early Production) 5.3L Engine361
Entertainment Systems362
Radio: Removal & Installation362
Cruise Control364
Instruments & Switches364
Cruise Control Switch364
Brake Light Switch: Removal & Installation364
Headlamp Switch: Removal & Installation365
Instrument Panel Cluster: Removal & Installation366
Front Fog Lamp: Removal & Installation367
Cornering and Fog Lamps (GMC and Chevrolet)367
Oldsmobile and Buick368
Front Fog Lamp (Buick)368
Headlamp: Removal & Installation369
Bulb Replacement369
Headlamp Assembly370
Chevrolet370
Aiming371
Low-Beam Headlight Pattern Alignment371
High-Beam Headlight Pattern Alignment372
Cargo Lamp: Removal & Installation373
Dome Lamp: Removal & Installation374
High Mount Stop Lamp: Removal & Installation375
Cornering Lamp: Removal & Installation375
Clearance Lamp: Removal & Installation376
Rear License Lamp: Removal & Installation377
Tail Lamp Assembly: Removal & Installation378
Windshield Wiper Arm: Removal & Installation379
Windshield Wiper Blade: Removal & Installation380
Wiper Blade (A), Wiper Arm (B), Wiper Blade Clip Locking Tab (C)380
Rear Window Wiper Arm: Removal & Installation381
Except GMC Envoy XUV381
GMC Envoy XUV382
Rear Window Wiper Blade: Removal & Installation383
Chevrolet, GMC (Except Envoy XUV), Oldsmobile, Buick, and Isuzu383
Saab and GMC Envoy XUV384
Windshield Wiper Motor: Removal & Installation385
Rear Window Wiper Motor: Removal & Installation (Except GMC Envoy XUV)386
Rear Window Wiper Motor Removal and Installation (GMC Envoy XUV)387
Windshield Wiper Switch388
Rear Window Wiper/Washer Switch: Removal & Installation388
Windshield Washer Pump: Removal & Installation389
Rear Window Washer Pump: Removal & Installation390
Doors391
Door Lock Actuator: Removal & Installation391
Liftgate Lock Actuator: Removal & Installation392
Window Regulator Motor: Removal & Installation (Front)393
Rear394
Short Wheel Base394
Rear Window Regulator Removal and Installation395
Long Wheel Base395
Power Seats398
Power Seat Adjuster Mechanism: Removal & Installation398
Front Seat Lumbar Assembly: Removal & Installation400
Drive Train: Precautions401
Automatic Transaxle403
Understanding the Automatic Transmission403
Torque Converter403
Lock-Up Converter405
Planetary Gearbox405
Low Range (Ring Gear Held)406
Drive Range (Sun Gear Held)406
Servos/Accumulators407
Hydraulic Control System407
Servo Operation407
Transmission: Removal & Installation (4.2L Engine)409
2002, 2003409
Torque Converter Access Plug Removal and Installation409
Transmission Removal and Installation (5.3L & 6.0L Engines)411
Transmission Fluid415
Fluid Level Checking415
Pre-Check Procedure415
Cold Check Procedure415
Hot Check Procedure416
Park/Neutral Position Switch: Removal & Installation417
J 41364-A Removal and Installation418
Adjustment419
Range Selector Lever Cable419
Range Selector Lever (A), Range Selector Lever Cable Bracket (B), Range Selector Lever Cable (C), Range Selector Lever Cable Retainer (D), Range Selector Lever Cable End (E)419
Floor Shift Control Assembly Removal and Installation420
Transmission Fluid Pan & Filter: Removal & Installation424
Driveline & U-Joints425
Front Propeller Shaft: Removal & Installation425
Front Axle Pinion Yoke425
Rear Propeller Shaft: Removal & Installation427
Rear Axle Pinion Yoke Retainer Removal and Installation427
Universal Joint: Removal & Installation429
External Snap Ring429
Nylon Injected Ring430
Differential Carrier Assembly: Removal & Installation (4.2L Engine)433
Upper Ball Pinch Nut and Bolt Removal and Installation433
Shock Module Retaining Nuts Removal and Installation434
Power Steering Gear Assembly Removal and Installation435
Power Steering Gear Assembly Removal and Installation (5.3L & 6.0L Engines)436
Axle Housing Bushing: Removal & Installation440
Intermediate Shaft Bearing & Oil Seal: Removal & Installation440
J 29369-2 and J 6125-B Installation440
Intermediate Shaft Bearing (Automatic 4WD)441
Intermediate Shaft Bearing (Selectable 4WD)441
Actuator Removal and Installation442
J 29369-2 and J 2619-01 Installation443
J 45225 and J 8029 Installation444
J 45359 and J 8092 Installation445
Drive Pinion Seal: Removal & Installation446
Drive Pinion Torque Measurement446
Drive Pinion Flange Removal446
Drive Pinion Seal Installation447
Rear Axle449
Axle Housing Assembly: Removal & Installation449
Axle Housing Bushing: Removal & Installation450
Axle Shaft: Removal & Installation450
J 45859 and J 2619-01 Installation451
Exle Shaft Bearing & Seal: Removal & Installation452
J 45857 and J 2619-01 Installation453
J 23690 and J 8092 Installation453
J 21128 Installation454
J 8614 Installation455
Transfer Case457
Front Output Shaft Seal: Removal & Installation457
Front Output Shaft Seal Installation458
Rear Output Shaft Seal: Removal & Installation459
Rear Output Shaft Seal Installation460
Transfer Case Assembly: Removal & Installation461
NP4 & NP8 Transfer Cases461
NR9 Transfer Case462
Half Shafts & CV-Joints464
Half Shaft: Removal & Installation464
CV-Joints466
Overhaul466
Double Offset Joint467
Except Double Offset Joint467
Removing the Outer Band from the CV-Boot469
Removing the Inner Band from the CV-Boot469
Removing the CV-Boot from the Joint Housing470
Removing the CV-Joint Housing Assembly471
Removing the CV-Joint471
Inspecting the CV-Joint Housing472
Removing the CV-Joint Outer Snap Ring472
Checking the CV-Joint Snap Ring for Wear473
CV-Joint Snap Ring (Typical)473
Removing the CV-Joint Assembly474
Removing the CV-Joint Inner Snap Ring474
Installing the CV-Joint Assembly (Typical)475
Steering and Suspension476
Steering478
Ignition Lock Cylinder Removal and Installation (Except Saab)479
Ignition Switch480
Ignition Switch Remova;/Installation481
Turn Signal/Multifuction Switch: Removal & Installation483
Power Steering Pump: Removal & Installation (4.2L Engine)484
Power Steering Pump Hoses Removal and Installation (5.3L/6.0L)486
Power Steering Hose Assembly: Removal & Installation (4.2L Engine)488
Power Steering Gear Oil Seal Removal491
Power Steering Gear Seal Installation492
Power Steering Gear Hoses Removal and Installation (5.3L/6.0L)493
Power Steering Cooler Hoses Removal and Installation494
Power Steering Hose Assembly Removal and Installation (5.3L/6.0L)495
Steering Gear: Removal & Installation498
Outer Tie Rod Retaining Nut Removal and Installation498
J 24319-B Steering Linkage and Tie Rod Puller499
Power Steering Gear Assembly Removal and Installation500
Power Steering Fluid501
Filling & Bleeding501
Steering Column: Removal & Installation502
J 42640 Installation502
Steering Wheel: Removal & Installation504
Tie Rod End: Removal & Installation506
Inner Tie Rod Assembly (Magnasteer)506
Left Inner Tie Rod Housing (A), Left Shock Dampener (B), Inner Tie Rod Asse,Bly (Quiet Valve) (C), Right Shock Dampener (D), Right Rack (E), Right Inn507
Rack (A), Inner Tie Rod (B)508
Outer Tie Rod End509
Outer Tie Rod Retaining Nut Removing and Installation509
Upper Control Arm Ball Joint: Removal & Installation511
Front Suspension511
Upper Ball Joint Removal512
Upper Ball Joint Installation513
Lower Control Arm Ball Joint: Removal & Installation514
Lower Ball Joint Removal514
Lower Ball Joint Installation515
Upper Control Arm: Removal & Installation516
Lower Control Arm: Removal & Installation518
Shock Absorber Module Yoke Nut Removal and Installation519
Lower Control Arm Removal and Installation520
Hub & Bearing: Removal & Installation521
Drive Axle Nut Removal and Installation521
Steering Knuckle: Removal & Installation523
Shock Absorber Module: Removal & Installation527
Shock Absorber: Removal & Installation529
J 45400530
Stabilizer Shaft: Removal & Installation532
Stabilizer Shaft Insulator Clamp Removal and Installation532
Rear Suspension534
Coil Spring: Removal & Installation534
Shock Absorber Mounting Bolt Removal and Installation534
Upper Control Arm Frame Mounting Bolt Removal and Installation537
Stabilizer Link Removal and Installation540
Stabilizer Shaft Insulator Clamp Mounting Nut Removal and Installation541
Rear Axle Brace: Removal & Installation542
Rear Axle Brace Tie Rod Mounting Bolt Removing and Installation542
Rear Axle Frame Mounting Nut Removal and Installation543
Wheels & Tires544
Wheels544
Inspection544
Wheel Lug Studs: Removal & Installation545
Front Disc Brakes W/Integral Hub & Rotor545
Rotor and Stud545
Pressing the Stud from the Rotor546
Stud Installation547
Front & Rear Disc Brakes W/Removable Rotor548
Wheel Lug Nut Tightening Sequence548
Removing Stud with C-Clamp and Socket549
Installing Lug Stud549
Rear W/Drum Brakes550
Exploded View of the Drum, Axle Flange and Stud551
Wheel Alignment554
Caster554
Camber555
Toe555
Frame Masalignment556
Toe-In556
Setback557
Subframe Setback557
Thrust Angles558
Lead/Pull558
Torque Steer559
Memory Steer559
Wander559
Preliminary Alignment Inspection559
Brakes561
Basic Operating Principles562
Disc Brakes564
Drum Brakes564
Power Boosters565
Brake Hoses and Pipes565
Hydraulic Brake System567
Master Cylinder Reservoir: Removal & Installation567
Brake Master Cylinder Assembly567
Master Cylinder Reservoir568
Brake Hoses and Steel Lines: Removal & Installation569
Stop Lamp Switch571
Master Cylinder: Removal & Installation572
Bench Bleeding574
Power Vacuum Brake Booster: Removal & Installation575
Stop Lamp Switch Removal and Installation576
Brake Booster Removal and Installation576
Brake Fluid577
Testing577
Vacuum Leak Test577
System Operation Test577
Bleeding the Brake System (ABS)578
Auto Bleed Procedure578
Disc Brakes579
Brake Caliper: Removal & Installation579
Front579
Brake Caliper Mounting Bolts Removal and Installation580
Rear Brake Caliper Hose Removal and Installation581
Rear Brake Caliper Removal and Installation582
Overhaul583
To Disassemble583
Using Compressed Air to Remove Piston583
Removing Piston from Caliper Bore584
Removing Anti-Rattle Clip584
Prying Edge of Boot585
Removing Boot from Caliper585
Removing Piston Seal586
To Assemble587
Installing Boot587
Bleeding Caliper588
Brake Rotor: Removing & Installation589
Front C-Clamp Installation589
Front Brake Rotor Removal and Installation590
Rear C-Clamp Installation591
Rear Brake Rotor Removal and Installation592
Brake Pads: Removal & Installation593
Brake Caliper594
Outboard Brake Pad Removal and Installation595
Inboard Brake Pad Removal and Installation596
Brake Pad Shim Removal and Installation597
Rear Brake Pad Removal and Installation599
Parking Brake600
Brake Shoes: Removing & Installation600
Actuator Mechanism (A), Parking Brake Shoe (B), Hold down Spring (C)600
Brake Rotor Measurement602
Brake Shoe Measurement602
Parking Brake Actuator: Removal & Installation604
Parking Brake Cables: Removal & Installation606
Parking Brake Equalizer606
J 37043607
Under Body Mounting Studs608
Park Brake Cable Retainers608
Parking Brake Frame Retainer609
Anti-Lock Brake System611
Electronic Brake Control Module: Removal & Installation611
Brake Pressure Modulator Valve (A), Electronic Brake Control Module (B), Brake Pressure Modulator Valve Bracket (C), Brake Pressure Modulator Valve Retaining Bolts (D)611
Brake Pressure Modulator Valve: Removal & Installation613
Front Wheel Speed Sensor: Removal & Installation615
Rear Wheel Speed Sensor: Removal & Installation617
Wheel Speed Sensor Ring: Removal & Installation618
J 45857 and J 2619-01 Installation618
Wheel Speed Sensor Ring Installation619
J 23690 and J 8092 Installation619
J 21128 Installation620
Air Conditioning & Heating Systems621
General Troubleshooting623
Leak Testing623
Manifold Gauge Set Components624
Refrigerant Recovery/Recycling Station624
Refrigerant Recovery & Recharging625
System Flushing625
Odor Correction626
Troubleshooting by Symptom627
Poor Heater System Performance627
Insufficient Defrosting628
Noise from Blower Motor628
Noise from A/C System629
Noise from the HVAC Housing (Evaporator Case)630
HVAC Control Module: Removal & Installation632
Accumulator: Removal & Installation633
Air Door Actuators: Removal & Installation634
Console Mode634
Left Side Air Temperature635
HVAC Control Module - Left Side635
Right Side Air Temperature636
Mode636
Defrost Valve637
Recirculation638
Recirculation Actuator Removal and Installation638
Front Auxiliary Blower Motor: Removal & Installation639
Rear Auxiliary Blower Motor: Removal & Installation640
Rear Auxiliary Blower Motor641
Blower Motor: Removal & Installation642
Blower Motor Control Pressure: Removal & Installation644
Automatic HVAC644
Blower Motor Resistor Assembly: Removal & Installation646
A/C Compressor: Removal & Installation (4.2L Engine)647
A/C Compressor Removal and Installation (5.3L/6.0L)648
Condenser: Removal & Installation650
Evaporator Core: Removal & Installation651
Front Heater Core: Removal & Installation652
Rear Heater Core: Removal & Installation653
Heater Inlet Hose: Removal & Installation654
Heater Hoses654
Heater Outlet Hose: Removal & Installation655
Front HVAC Module: Removal & Installation656
Rear Auxiliary HVAC Module: Removal & Installation658
Under Vehicle Rear Auxiliary HVAC Connections658
Instrument Panel: Removal & Installation661
Lower Instrument Panel Retaining Volts662
Upper Instrument Panel Retaining Volts663
Expansion (Orifice Tube): Removal & Installation665
Ambient Air Temperature Sensor: Removal & Installation666
Inside Air Temperature Sensor: Removal & Installation667
A/C Refrigerant Pressure Sensor: Removal & Installation669
Sun Load Sensor: Removal & Installation670
Upper Left Air Temperature Sensor: Removal & Installation671
Lower Left Air Temperature Sensor: Removal & Installation672
Upper Right Air Temperature Sensor: Removal & Installation673
Lower Right Air Temperature Sensor: Removal & Installation674
A/C Low Pressure Switch: Removal & Installation675
A/C Specifications676

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