DEFINITION OF CAUTION, NOTICE, & IMPORTANT
The diagnosis & repair procedures in the GM Service Manual contain both general & specific Cautions, Notices, & Importants. GM is dedicated to the presentation of service information that helps the technician to diagnose & repair the systems necessary for the proper operation of the vehicle, however, certain procedures may present a hazard to the technician if they are not followed in the recommended manner. Cautions, Notices, & Importants are elements designed to prevent these hazards, however, not all hazards can be foreseen. This information is placed at strategic locations within the service manual. This information is designed to prevent the following from occurring
- Serious bodily injury to the technician.
- Damage to the vehicle.
- Unnecessary vehicle repairs.
- Unnecessary component replacement.
- Improper repair or replacement of vehicle components. Any caution or notice that appears in general information is referenced from the individual service categories.
CAUTION Defined
When encountering a CAUTION, you will be asked to take a necessary action or not to take a prohibited action. If a CAUTION is not heeded, the following consequences may occur
- Serious bodily injury to the technician.
- Serious bodily injury to other technicians in the workplace area.
- Serious bodily injury to the driver and/or passenger(s) of the vehicle, if the vehicle has been improperly repaired.
NOTICE Defined
Notices call special attention to a necessary action or to a prohibited action. If a NOTICE is not heeded, the following consequences may occur
- Damage to the vehicle.
- Unnecessary vehicle repair.
- Unnecessary component replacement.
- Improper operation or performance of the system or component under repair.
- Damage to any systems or components which are dependent upon the proper operation of the system or component under repair.
- Improper operation or performance of any systems or components which are dependent upon the proper operation or performance of the system or component under repair.
- Damage to fasteners, basic tools, or special tools.
- The leakage of coolant, lubricant, or other vital fluids.
IMPORTANT Defined
IMPORTANT statements emphasize a necessary characteristic of a diagnostic or repair procedure. IMPORTANT statements are designed to do the following
- Clarify a procedure.
- Present additional information for accomplishing a procedure.
- Give insight into the reason or reasons for performing a procedure in the manner recommended.
- Present information that will help to accomplish a procedure in a more effective manner.
- Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater ease.
ABS COMPONENT HANDLING CAUTION
| CAUTION | Certain components in the Anti-lock Brake System (ABS) are not intended to be serviced individually. Attempting to remove or disconnect certain system components may result in personal injury and/or improper system operation. Only those components with approved removal & installation procedures should be serviced. |
ACTIONS TO TAKE WHEN WORKING WITH FUEL CAUTION
| CAUTION | Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire & increased exposure to vapors: Use forced air ventilation such as a fan set outside of the trunk. Plug or cap any fuel system openings in order to reduce fuel vapor formation. Clean up any spilled fuel immediately. Avoid sparks & any source of ignition. Use signs to alert others in the work area that fuel system work is in process. |
APPROVED EQUIPMENT FOR COLLISION REPAIR CAUTION
| CAUTION | To avoid personal injury when exposed to welding flashes or to galvanized (Zinc Oxide) metal toxic fumes while grinding/cutting on any type of metal or sheet molded compound, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs, welding gloves, & protective clothing. |
ASSISTANT DRIVING CAUTION
| CAUTION | An assistant should drive the vehicle while the technician checks for the location of the reported condition. Otherwise, personal injury could result. |
BATTERIES PRODUCE EXPLOSIVE GASES CAUTION
| CAUTION | Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: Always shield your eyes. Avoid leaning over the battery whenever possible. Do not expose the battery to open flames or sparks. Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately & thoroughly. Get medical help. |
BATTERY DISCONNECT CAUTION
| CAUTION | Before servicing any electrical component, the ignition key must be in the OFF or LOCK position & all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. |
BRAKE DUST CAUTION
| CAUTION | Avoid taking the following actions when you service wheel brake parts: Do not grind brake linings. Do not sand brake linings. Do not clean wheel brake parts with a dry brush or with compressed air. Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne. |
BRAKE FLUID IRRITANT CAUTION
| CAUTION | Brake fluid may irritate eyes & skin. In case of contact, take the following actions: Eye contact-rinse thoroughly with water. Skin contact-wash with soap & water. If ingested-consult a physician immediately. |
BRAKE PIPE REPLACEMENT CAUTION
| CAUTION | Always use double-walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended & may cause brake system failure. Carefully route & retain replacement brake pipes. Always use the correct fasteners & in the original location for replacement brake pipes. Failure to properly route & retain brake pipes may cause damage to the brake pipes & brake system resulting in personal injury. |
BREATHING R-134A CAUTION
| CAUTION | Avoid breathing the A/C Refrigerant 134a (R-134a) & the lubricant vapor or the mist. Exposure may irritate the eyes, nose, & throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health & safety information may be obtained from the refrigerant & lubricant manufacturers. |
CLEANING SOLVENT CAUTION
| CAUTION | Bodily injury may occur if the cleaning solvent is inhaled or exposed to the skin. |
CLUTCH DUST CAUTION
| CAUTION | When servicing clutch parts, do not create dust by grinding or sanding the clutch disc or by cleaning parts with a dry brush or with compressed air. A water-dampened cloth (NOT SOAKED) should be used. The clutch disc contains asbestos fibers which can become airborne if dust is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm. |
DEFROSTER OUTLET CAUTION
| CAUTION | If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury. |
DOOR OUTER PANEL REPLACEMENT CAUTION
| CAUTION | Inspection of the door guard beam for damage must be performed before replacement of the door outer panel. If damage to the door guard beam is found the door must be replaced. Failure to do so may compromise the structural integrity of the vehicle & may cause personal injury if the vehicle is involved in a collision. |
ELECTRIC COOLANT FAN CAUTION
| CAUTION | An electric fan under the hood can start up even when the engine is not running & can injure you. Keep hands, clothing & tools away from any underhood electric fan. |
EXPRESS WINDOW DOWN CAUTION
| CAUTION | Disconnect the power window switch when working inside the driver door. When operated, the Express Up/Down Feature allows the door window to move very quickly, without stopping, which could cause personal injury. |
EYE PROTECTION CAUTION
| CAUTION | Approved safety glasses & gloves should be worn when performing this procedure to reduce the chance of personal injury. |
FOAM SOUND DEADENERS CAUTION
| CAUTION | Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result. |
FLOOR JACK CAUTION
| CAUTION | Floor jack must remain under the lower control arm during removal and installation to retain the lower control arm in position. Failure to do so could result in personal injury. |
FUEL & EVAP PIPE CAUTION
| CAUTION | In order to reduce the risk of fire & personal injury observe the following items: Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes. Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak. Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection & prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell & may prevent proper reconnection if not lubricated). |
FUEL GAGE LEAK CAUTION
| CAUTION | Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire & personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. |
FUEL PIPE FITTING CAUTION
| CAUTION | Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire & personal injury. This will ensure proper reconnection & prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell & may prevent proper reconnection if not lubricated. |
FUEL RAIL STOP BRACKET INSTALLATION CAUTION
| CAUTION | The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket is not installed & the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire & personal injury from burns. |
FUEL STORAGE CAUTION
| CAUTION | Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. |
FUEL VAPORS IN EVAPORATIVE EMISSION (EVAP) COMPONENTS CAUTION
| CAUTION | Do not breathe the air through the EVAP component tubes or hoses. The fuel vapors inside the EVAP components may cause personal injury. |
GASOLINE/GASOLINE VAPORS CAUTION
| CAUTION | Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. |
GLASS & SHEET METAL HANDLING CAUTION
| CAUTION | When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses & gloves in order to reduce the chance of personal injury. |
HALOGEN BULB CAUTION
| CAUTION | Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: Turn off the lamp switch & allow the bulb to cool before changing the bulb. Leave the lamp switch OFF until the bulb change is complete. Always wear eye protection when changing a halogen bulb. Handle the bulb only by its base. Avoid touching the glass. Keep dirt & moisture off the bulb. Properly dispose of the used bulb. Keep halogen bulbs out of the reach of children. |
HOOD HOLD-OPEN DEVICE CAUTION
| CAUTION | When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. |
HOT EXHAUST SYSTEM CAUTION
| CAUTION | While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system. |
LOWER O-RING REMOVAL CAUTION
| CAUTION | Verify that the lower (small) O-ring of each injector does not remain in the lower manifold in order to reduce the risk of fire & personal injury. If the O-ring is not removed with the injector, the replacement injector with new O-rings will not seat properly in the injector socket. Improper seating could cause a fuel leak. |
MOVING PARTS & HOT SURFACES CAUTION
| CAUTION | Avoid contact with moving parts & hot surfaces while working around a running engine in order to prevent physical injury. |
PROTECTIVE GOGGLES & GLOVE CAUTION
| CAUTION | Always wear protective goggles & gloves when removing exhaust parts as falling rust & sharp edges from worn exhaust components could result in serious personal injury. |
RADIATOR CAP REMOVAL CAUTION
| 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 & steam under pressure if radiator cap or surge tank cap is removed while the engine & radiator are still hot. |
RELIEVING FUEL PRESSURE CAUTION
| CAUTION | Remove the fuel tank cap & relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. |
REPLACEMENT CARPET CAUTION
| CAUTION | In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness & material size as the original installation. Always return the carpet to the original location. |
ROAD TEST CAUTION
| CAUTION | Road test a vehicle under safe conditions & while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury & vehicle damage. |
SAFETY GLASSES CAUTION
| CAUTION | Wear safety glasses in order to avoid eye damage. |
SAFETY GLASSES & COMPRESSED AIR CAUTION
| CAUTION | Wear safety glasses when using compressed air in order to prevent eye injury. |
SAFETY GOGGLES & FUEL CAUTION
| CAUTION | Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash. |
SERVICING THE SIR SYSTEM CAUTION
| CAUTION | When performing service on or around the SIR components or the SIR wiring, follow the procedures listed below in order to temporarily disable the SIR system. Failure to follow the procedures could result in the following: Air bag deployment. Personal injury. Otherwise unneeded SIR system repairs. |
SIR CAUTION
| CAUTION | When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling & Enabling Zones. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. |
SIR DEPLOYED INFLATOR MODULES ARE HOT CAUTION
| CAUTION | After deployment, the metal surfaces of the SIR component may be very hot. To help avoid a fire or personal injury: Allow sufficient time for cooling before touching any metal surface of the SIR component. Do not place the deployed SIR component near any flammable objects. |
SIR HANDLING CAUTION
| CAUTION | When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. |
SIR INFLATOR MODULE COIL CAUTION
| CAUTION | Improper routing of the wire harness assembly may damage the inflatable restraint steering wheel module coil. This may result in a malfunction of the coil, which may cause personal injury. |
SIR INFLATABLE MODULE DEPLOYMENT OUTSIDE VEHICLE CAUTION
| CAUTION | When deploying a SIR component for disposal, perform the deployment procedures in the order listed. Failure to observe the procedures in the order listed may result in personal injury. |
SIR INFLATOR MODULE DISPOSAL CAUTION
| CAUTION | In order to prevent accidental deployment & the risk of personal injury, do not dispose of an undeployed inflator modules as normal shop waste. Undeployed inflator modules contain substances that could cause severe illness or personal injury if their sealed containers are damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed inflator module. Failure to observe the following disposal methods may be a violation of federal, state, or local laws. |
SIR INFLATOR MODULE HANDLING & STORAGE CAUTION
| CAUTION | When carrying an undeployed inflator module: Do not carry the inflator module by the wires or connector. Make sure the air bag opening points away from you. |
When storing an undeployed inflator module
- Make sure the air bag opening points away from the surface on which the inflator module rests.
- Provide free space for the air bag to expand in case of an accidental deployment.
- When storing a steering column, do not rest the column with the air bag opening facing down & the column vertical. Lay the column on its side. Failure to observe these guidelines may result in personal injury.
SIR SPECIAL TOOL CAUTION
| CAUTION | Failure to observe the special tool recommendations & instructions could cause SIR deployment, personal injury, or unnecessary SIR system repairs. |
TILT SPRING CAUTION
| CAUTION | The tilt spring & the spring guide are under pressure. The tilt spring & the spring guide may become a projectile. Secure the spring with locking pliers during removal. Secure the spring with locking pliers during installation. Bodily injury may result during removal & installation of the tilt spring & the spring guide. Always use caution during removal & installation of the tilt spring & the spring guide. |
VALVE SPRINGS CAN BE TIGHTLY COMPRESSED CAUTION
| CAUTION | Valve springs can be tightly compressed. Use care when removing retainers & plugs. Personal injury could result. |
VEHICLE LIFTING CAUTION
| CAUTION | To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle & the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. |
WINDOW RETENTION CAUTION
| CAUTION | When replacing stationary windows, use Urethane Adhesive Kit GM P/N 12346392 (Canadian P/N 10952983), or a urethane adhesive system meeting GM Specification GM 3651G, to maintain original installation integrity. Failure to use the urethane adhesive kit will result in poor retention of the window which may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury. |
WORK STALL TEST CAUTION
| CAUTION | One or more of the following guidelines may apply when performing specific required tests in the work stall: When a test requires spinning the drive wheels with the vehicle jacked up, adhere to the following precautions: Do not exceed 56 km/h (35 mph) when spinning one drive wheel with the other drive wheel stopped. This limit is necessary because the speedometer indicates only one-half the actual vehicle speed under these conditions. Personal injury may result from excessive wheel spinning. If all of the drive wheels are spinning at the same speed, do not exceed 112 km/h (70 mph). Personal injury may result from excessive wheel spinning. All persons should stay clear of the rotating components & the balance weight areas in order to avoid possible personal injury. When running an engine in the repair stall for an extended period of time, use care not to overheat the engine & the transmission. When a test requires jacking up the vehicle & running with the wheels & brake rotors removed, adhere to the following precautions: Support the suspension at normal ride height. Do not apply the brake with the brake rotors removed. Do not place the transmission in PARK with the drive axles spinning. Turn Off the ignition in order to stop the powertrain components from spinning. |
AIR IN THE POWER STEERING SYSTEM NOTICE
Note. If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time.
ANTI-CORROSION MATERIALS NOTICE
Note. Anti-corrosion compounds have been applied to the interior surfaces of some metal panels to provide rust resistance. When servicing these panels in areas on which this material has been disturbed, or when installing new panels, avoid corrosion damage by coating with anti-corrosion compound.
AUTOMATIC TRANSMISSION SHIFT LOCK CONTROL NOTICE
Note. Do not use excessive force when removing the automatic transmission shift lock control from the steering column. Using excessive force may cause damage to the automatic transmission shift lock control and/or the steering column.
BELT DRESSING NOTICE
Note. Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.
BRAKE CALIPER NOTICE
Note. Support the caliper with a piece of wire to prevent damage to the brake line.
BRAKE CALIPER SUPPORTING TO PREVENT HOSE DAMAGE NOTICE
Note. Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount & the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose & in turn may cause a brake fluid leak.
BRAKE FLUID EFFECTS ON PAINT & ELECTRICAL COMPONENTS NOTICE
Note. Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces & cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid.
CLEAN, DRY, LOW PRESSURE GAS SOURCE NOTICE
Note. Use the EVAP Pressure/Purge Diagnostic Station J 41413 in order to provide a clean, dry, low pressure gas source. Do not substitute any other pressurized gas source. Damage may result to the EVAP system.
CLEARCOAT/ULTRAVIOLET SCREENERS NOTICE
Note. Removing more than 0.5 mils of the clearcoat can result in early paint failure. The clearcoat contains ultraviolet screeners. Do not finesse sand more than what is required to remove the defect.
COMPONENT FASTENER TIGHTENING NOTICE
Note. Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.
DIFFERENTIAL HOUSING COVER & GASKET REMOVAL NOTICE
Note. When removing the differential case from the axle housing, do not damage the cover gasket surface. If the cover gasket surface is damaged, lubricant may leak from the axle and cause premature failure of the axle assembly.
DO NOT DEPRESS BRAKE PEDAL WITH ROTORS/DRUMS REMOVED NOTICE
Note. DO NOT depress the brake pedal with the brake rotors and/or the brake drums removed, or with the brake calipers repositioned away from the brake rotors, or damage to the brake system may result.
ELECTRICAL WIRING ROUTING NOTICE
Note. Note the correct routing of the electrical wiring. Failure to reinstall the wiring properly could result in damage to the wiring.
EMISSION MODIFICATION NOTICE
Note. Modifications made to the following can affect the vehicle's emission controls & may cause the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon lamp to illuminate: The engine. The transmission. The exhaust. The fuel system.
Replacement tires that do not meet the same Tire Performance Criteria (TPC) of the original tires can also affect the vehicle's emission controls. This may also cause the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon lamp to illuminate.
Modifications to these systems or the installation of incorrect TPC tires could lead to repairs that are not covered by the manufacturer's warranty. This may also cause a required Emission Inspection/Maintenance test to fail.
ENGINE EMISSION NOTICE
Note. Modifications made to the engine or its individual components can effect the vehicle's emission controls & may cause the Malfunction Indicator Lamp (MIL), Check Engine, or Service Engine Soon lamp to illuminate. Modifications may also cause the vehicle to fail a required Emission Inspection/Maintenance test.
ENGINE LIFTING NOTICE
Note. When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Lifting the engine in an unapproved manner may cause component damage.
ENGINE MOUNTING NOTICE
Note. Broken engine mountings can cause misalignment of certain drive-train components. Misalignment of drive-train components causes eventual destruction of the drive-train components.
If one engine mount breaks, the rest of the engine mounts will have increased stress put on them. This could cause the rest of the engine mounts to break.
EXCESSIVE FORCE & OXYGEN SENSOR NOTICE
Note. The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
EXHAUST SYSTEM INSPECTION NOTICE
Note. When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating of the floor pan & possible damage to the passenger compartment insulation & trim materials.
EXTERIOR TRIM EMBLEM REMOVAL NOTICE
Note. Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name plate.
FASTENER NOTICE
Note. Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque & joint clamping force & may damage the fastener. Use the correct tightening sequence & specifications when installing fasteners in order to avoid damage to parts and systems.
FLEX DECOUPLER NOTICE
Note. Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches.
FUEL & EVAPORATIVE EMISSION (EVAP) HOSE/PIPE CONNECTION CLEANING NOTICE
Note. Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections The hose connections The areas surrounding the connections
FUEL INJECTOR BALANCE TEST NOTICE
Note. Do not repeat any portion of this test before running the engine in order to prevent the engine from flooding.
FUEL PRESSURE NOTICE
Note. Do not allow the fuel pressure to exceed the specified value because damage to the fuel pressure regulator or the fuel pressure gage may result.
FUEL SYSTEM GROUND NOTICE
Note. Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. Do not repair sections of fuel pipes.
FUEL TANK STRAP FASTENER NOTICE
Note. Tighten the strap fasteners by steps, alternating between the fasteners, until the specified torque is reached. A failure to tighten the strap fasteners as specified will cause the bottom of the tank to flex upward. This will result in the fuel gauge indicating that there is fuel remaining in the tank when the tank is empty.
HANDLING BEARING INSERTS NOTICE
Note. DO NOT shim, scrape, or file bearing inserts. DO NOT touch the bearing surface of the insert with bare fingers. Skin oil and acids will etch the bearing surface.
HANDLING ESD SENSITIVE PARTS NOTICE
Note. Electrostatic discharge (ESD) can damage many solid-state electrical components. ESD susceptible components may or may not be labeled with the ESD symbol. Handle all electrical components carefully. Use the following precautions in order to avoid ESD damage
- Touch a metal ground point in order to remove your body's static charge before servicing any electronic component; especially after sliding across the vehicle seat.
- Do not touch exposed terminals. Terminals may connect to circuits susceptible the ESD damage.
- Do not allow tools to contact exposed terminals when servicing connectors.
- Do not remove components from their protective packaging until required to do so.
- Avoid the following actions unless required by the diagnostic procedure: Jumpering or grounding of the components or connectors. Connecting test equipment probes to components or connectors. Connect the ground lead first when using test probes.
- Ground the protective packaging of any component before opening. Do not rest solid-state components on metal workbenches, or on top of TVs, radios, or other electrical devices.
HANDLING IAC VALVE NOTICE
Note. If the IAC valve has 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. Also, DO NOT soak the IAC valve in any liquid cleaner or solvent, as damage may result.
HEATED OXYGEN & OXYGEN SENSOR NOTICE
Note. Do not remove this pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector & the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal & heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference & degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor
- Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance.
- Do not damage the sensor pigtail & harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor & cause performance problems.
- Ensure the sensor or vehicle lead wires should not be bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire.
- Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance.
- Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp & Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed.
IGNITION OFF WHEN DISCONNECTING BATTERY NOTICE
Note. Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.
INSTALLING HOSES WITHOUT TWISTS OR BENDS NOTICE
Note. The inlet & outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage.
INSTRUMENT PANEL CLUSTER (IPC) SERVICING NOTICE
Note. Whenever the Instrument Panel Cluster (IPC) is removed from the vehicle, DO NOT set the IPC on its face for more than 15 minutes or damage to the fluid filled air core gages may result.
LATCHED DTC B1018, B1024 NOTICE (SDM-RSD)
Note. When DTC B1018 or B1024 has been set it is necessary to replace the inflatable restraint Sensing & Diagnostic Module (SDM). Setting DTC B1018 or B1024 will also cause DTC B1071 to set. When a scan tool clear codes command is issued & the malfunction is no longer present, DTC B1018 or B1024 & DTC B1071 will remain current. Make sure that the short to ground condition is repaired prior to installing a replacement SDM to avoid damaging the SDM.
LIFTGATE ASSIST ROD NOTICE
Note. Apply pressure only at the end of the liftgate/hood assist rod that you are removing or attaching. Do NOT apply pressure to the middle of the rod because damage or bending will result.
MACHINED SURFACE DAMAGE NOTICE
Note. Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to the machined surface can cause leakage.
NYLON FUEL LINES NOTICE
Note. Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.
OBDII SYSTEM DESCRIPTION NOTICE
Note. The OBDII symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit.
OBDII SYMBOL DESCRIPTION NOTICE
Note. The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails & causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit.
OXYGEN SENSOR NOTICE
Note. Handle the oxygen sensors carefully in order to prevent damage to the component. Keep the electrical connector and the exhaust inlet end free of contaminants. Do not use cleaning solvents on the sensor. Do not drop or mishandle the sensor.
PCM & ESD NOTICE
Note. Do not touch the connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage to the PCM.
PINION FLANGE/YOKE INSTALLATION NOTICE
Note. DO NOT hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.
PIPE WRENCH POSITIONING NOTICE
Note. The pipe wrench must be placed at the valve end of the steering gear and positioned up against the inner tie rod housing. Placing the pipe wrench in any other location will cause damage to the steering gear.
POWER STEERING HOSE DISCONNECTED NOTICE
Note. Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid & damage to the system.
PROPERLY SECURED EVAPORATIVE EMISSION (EVAP) PIPE NOTICE
Note. Properly secure the EVAP pipe in order to prevent chafing of the pipe.
RING GEAR REMOVAL NOTICE
Note. DO NOT pry the ring gear from the differential case. Prying the ring gear from the differential case may cause damage to the ring gear and/or the differential case.
SEALANT NOTICE
Note. Do not allow the RTV sealant to enter any blind threaded hole. RTV sealant that is allowed to enter a blind threaded hole can cause hydraulic lock of the fastener when the fastener is tightened. Hydraulic lock of a fastener can lead to damage to the fastener and/or the components. Hydraulic lock of a fastener can also prevent the proper clamping loads to be obtained when the fastener is tightened. Improper clamping loads can prevent proper sealing of the components allowing leakage to occur. Preventing proper fastener tightening can allow the components to loosen or separate leading to extensive engine damage.
SERVICE PROGRAMMING SYSTEM (SPS) NOTICE
Note. Before programming a control module, the following must be observed, or control module damage may occur: The Tech 2 & the terminal must have the latest software. The vehicle battery must be fully charged. The battery voltage should be between 12-14 volts. The Tech 2 & the terminal cable connections must be secure. A battery charger must NOT be connected to the battery when programming a control module.
SERVICING AND REPLACING SEAT BELTS NOTICE
Note. To prevent possible seat belt damage, refer to the following items before servicing or replacing lap and shoulder belts, including single loop belt systems: Lap and shoulder belts will be serviced as follows: Replace only the part in question. Do not intermix standard and deluxe belts on front or rear seats. All attachment hardware must be replaced, not reused. Keep sharp edges and damaging objects away from belts. Avoid bending or damaging any portion of the belt buckle or latch plate. Do not bleach or dye belt or strap webbing. Clean with a mild soap solution and water. When installing lap or shoulder belt anchor bolts, start the bolts by hand to ensure that the bolts are threaded straight. Do not attempt repairs on lap or shoulder belt retractor mechanisms to lap belt retractor covers. Replace defective assemblies with new service replacement parts. Do not attempt to remove the seat belt retractor cover. The cover and the long rivet securing the cover to the retractor are not available as service replacement parts.
SERVICING THE LEVEL SENSOR NOTICE
Note. Before servicing the level sensor, it is necessary to hinge the sensor arm into a horizontal position prior to removal. Failure to do so will result in breakage of the sensor.
SILICON CONTAMINATION OF HEATED OXYGEN SENSORS NOTICE
Note. Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S & visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor.
SINGLE CYLINDER FLOODING NOTICE
Note. In order to prevent flooding of a single cylinder & possible engine damage, relieve the fuel pressure before performing the fuel injector coil test procedure.
SPARK PLUG BOOT REMOVAL NOTICE
Note. Use only the spark plug boot special removal tool to remove the spark plug boots. Prying or using regular pliers could damage the boots.
SPECIAL FASTENER NOTICE
Note. This bolt is designed to permanently stretch when tightened. The correct part number fastener must be used to replace this type of fastener. Do not use a bolt that is stronger in this application. If the correct bolt is not used, the parts will not be tightened correctly. The system or the components may be damaged.
STABILIZER SHAFT LINK DAMAGE NOTICE
Note. Do not pry on the stabilizer shaft link. Use care when removing or installing the stabilizer shaft link in order to avoid tearing or puncturing the stabilizer shaft link boot. Damage to the stabilizer shaft link boot will lead to damage to the stabilizer shaft link.
STEERING GEAR PRELOAD ADJUSTMENT NOTICE
Note. Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod could result in damage to the pinion and the steering gear.
STEERING WHEEL IN THE FULL TURN POSITION NOTICE
Note. Do not hold the steering wheel in the full turn position longer than 5 seconds, as damage to the steering pump may result.
SUSPENSION SPRING HANDLING NOTICE
Note. Care should be taken to avoid chipping or cracking the spring coating when handling the front suspension coil spring. Failure to observe this notice may result in spring breakage.
TEST LAMP TO IGNITION CONTROL MODULE CIRCUIT CONNECTOR NOTICE
Note. Do not leave the test lamp connected to the PCM IC circuit connector for longer than 5 seconds at a time. Failure to do so may damage the ignition coil and/or the Ignition Control Module.
TEST PROBE NOTICE
Note. Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals & cause incorrect measurements.
TRANSFER CASE SEAL REMOVAL NOTICE
Note. Do not damage the sealing surfaces of the transfer cases or the shafts when prying the seals for removal. Damaging the sealing surface may cause leakage or require replacement of the damaged component.
VALVE LIFTER PRIMING NOTICE
Note. Ensure each valve lifter is filled with clean engine oil and the valve lifter does not tip over (plunger down) before the installation of the valve lifters. The loss of oil in the valve lifter lower pressure chamber or the dry stroking/cycling of the valve lifter plunger will allow air to travel into the high pressure chamber of the valve lifter. Air in the high pressure chamber of the valve lifter may not be purged causing extensive engine component damage.