General Information Buick Encore I

Arrows and Symbols

This service manual uses various symbols in order to describe different service operations.

Scheme 1

Acronyms and Units

Acronyms

Units

Customer Concern Verification Sheets

The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time.

Scheme 2

The vehicle identification number (VIN) plate is the legal identifier of the vehicle. The VIN plate is located on the upper left corner of the instrument panel (I/P) and can be seen through the windshield from the outside of the vehicle

Vehicle, Engine and Transmission ID and VIN Location, Derivative and Usage (Encore)

Vehicle, Engine and Transmission ID and VIN Location, Derivative and Usage (Trax)

The vehicle identification number (VIN) plate is the legal identifier of the vehicle. The VIN plate is located on the upper left corner of the instrument panel (I/P) and can be seen through the windshield from the outside of the vehicle

Vehicle, Engine and Transmission ID and VIN Location, Derivative and Usage (Trax)

1.4L Engine ID and VIN Derivative Location

Refer to Engine Identification .

Scheme 3

Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label

RPO Code List (Encore)

The following table provides the description of the Regular Production Option (RPO) codes that are available on the vehicle. The vehicle's RPO list is printed on the Service Parts Identification Label.

RPO Code List (Trax)

The following table provides the description of the Regular Production Option (RPO) codes that are available on the vehicle. The vehicle's RPO list is printed on the Service Parts Identification Label.

Metric Fasteners

This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength.

A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive® or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive® recess head screws.

GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches.

Scheme 4

The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face.

The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following

1. Lower strength
2. No numbered head marking system
3. Wrong thread pitch

The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications

1. M6.0 X 1
2. M8 X 1.25
3. M10 X 1.5
4. M12 X 1.75
5. M14 X 2.00
6. M16 X 2.00

Prevailing Torque Fasteners

Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening.

All Metal Prevailing Torque Fasteners

These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener.

Nylon Interface Prevailing Torque Fasteners

These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads.

Adhesive Coated Fasteners

These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener.

Scheme 5

A prevailing torque fastener may be reused ONLY if

1. The fastener and the fastener counterpart are clean and not damaged
2. There is no rust on the fastener
3. The fastener develops the specified minimum torque against its counterpart prior to the fastener seating

Metric Prevailing Torque Fastener Minimum Torque Development

English Prevailing Torque Fastener Minimum Torque Development

Thread Inserts

General Purpose Thread Repair Kits.

These kits are available commercially.

Repair Procedure

1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth.
2. Drill out the damaged threads. Clean out any chips.
3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads.
4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel.
5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert.
6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift.

Registered and Non-Registered Trademarks

Listed below are Registered Trademarks (®) or Non-Registered Trademarks (™) which may appear in this service manual.

Registered and Non-Registered Trademarks

Door Lock and Ignition Lock Folding and Non-Folding Key Cutting

High Security keys are available from the service parts system.

Obtain the key code from the security card or from the GM Dealer World, Parts, Key Code Look Up system.

If you have the key code and access to a Triax-E., BD Laser or other code key cutting machine from the GM Dealer Equipment Catalog, you may cut a new key.

If you have the original key and access to a Matrix S, BD Laser or other key duplicating machine, you may duplicate the key.

If you do not have a high security key cutting machine, order the side cut key from the service parts system. Include the key code in the NOTE field. Indicate the timing and the method of the shipment.

Inspect the new key operation in the lock cylinder. Ensure the new key operates effectively.

Front Side Door Lock Cylinder Coding (Free Wheeling)

Special Tools

BO-49753 Assembly Tool

Scheme 6

The door lock cylinder uses 8 of the 8 cut positions. The tumbler positions are staggered from side to side, 4 on one side and 4 on the other, are not self-retaining, and are not snap in.

1. Hold the door lock cylinder (1) so the side with the 4 tumbler spring pockets faces up, pocket nearest to the cylinder head.
2. Insert the tumbler springs (2) into the 4 spring pockets. This side uses left tumblers.
3. Install the tumbler (3) for key cut position one in the slot nearest to the front of the lock cylinder. Install the remaining tumblers, key cut positions 3, 5, and 7, following the key code and same process. Press the tumblers in place until they are secure.
4. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flush with the lock cylinder body.
5. Turn the cylinder so the side with the 4 tumbler spring wells faces up. This side uses right tumblers.
6. Insert the tumbler springs into the 4 spring pockets.
7. The first tumbler closest to the front of the lock cylinder to be loaded will be the second key cut position, the second number in the key code. Install the remaining tumblers for the key cut positions 4, 6, and 8. Press the tumblers in place until they are secure.
8. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flush with the lock cylinder body.
9. Insert the key and lightly lubricate the cylinder body diameter and tumbler surfaces and a small amount in the head of the cylinder using the supplied grease.
10. Insert the sleeve (4) onto the cylinder assembly.
11. Insert the clutch (5) and driver (6) onto the cylinder (1).
12. Load the cylinder into the BO-49753 assembly tool so that the clutch (1) indexes with the notch in the opening of the tool (2).
13. Load the assembly tool with the lock cylinder into a vice and tighten the vice ONLY enough to hold the tool and lock the cylinder in place.
14. Insert the roll pin (7) into the driver (6) and install it using a 1/16 inch pin punch.
15. Insert the buffer (8) in the case (9), verify the buffer is properly seated.
16. Install the free wheel pin (11) in the sleeve (4) and clutch (5) and insert the assembly into the case (9).
17. With the lock cylinder assembly installed in the case (9), install the retainer (10) and stake the retainer in place using a small punch and hammer to peen the case material onto the exposed ends of the installed retainer (10).
18. Insert the key into the lock and function the lock to check for proper assembly and smooth operation.

Scheme 7

The door lock cylinder uses 8 of the 8 cut positions. The tumbler positions are staggered from side to side, 4 on one side and 4 on the other, are not self-retaining, and are not snap in.

1. Hold the door lock cylinder (1) so the side with the 4 tumbler spring pockets faces up, pocket nearest to the cylinder head.
2. Insert the tumbler springs (2) into the 4 spring pockets. This side uses left tumblers.
3. Install the tumbler (3) for key cut position one in the slot nearest to the front of the lock cylinder. Install the remaining tumblers, key cut positions 3, 5, and 7, following the key code and same process. Press the tumblers in place until they are secure.
4. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flush with the lock cylinder body.
5. Turn the cylinder so the side with the 4 tumbler spring wells faces up. This side uses right tumblers.
6. Insert the tumbler springs into the 4 spring pockets.
7. The first tumbler closest to the front of the lock cylinder to be loaded will be the second key cut position, the second number in the key code. Install the remaining tumblers for the key cut positions 4, 6, and 8. Press the tumblers in place until they are secure.
8. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flush with the lock cylinder body.
9. Insert the key and lightly lubricate the cylinder body diameter and tumbler surfaces and a small amount in the head of the cylinder using the supplied grease.
10. Insert the sleeve (4) onto the cylinder assembly.
11. Insert the assembly into the case (5).
12. With the lock cylinder assembly installed in the case (5), install the retainer (6) and stake the retainer in place using a small punch and hammer to peen the case material onto the exposed ends of the installed retainer (6).
13. Insert the key into the lock and function the lock to check for proper assembly and smooth operation.

Scheme 8

The ignition lock cylinder uses 8 key cut positions, 1-8. The ignition cylinder tumblers (3) are located on alternate sides of the cylinder (5). They are not snap-in and are not self-retaining. It follows the key code with the first tumbler being the first depth of the key code, closest to the head of the key.

1. Hold the ignition cylinder assembly (5) so the side with the tumbler spring pocket located closest to the head of the cylinder is facing up.
2. Insert the tumbler spring (7) into each of the 4 spring pockets of the cylinder assembly. This side of the cylinder used left tumblers.
3. The first tumbler (3) to be loaded will be the first key cut position, which is the first number in the key code. Install the tumbler in the slot over the spring. Install the remaining right tumblers following the key code and same process, pressing the tumblers in place until they are secure.
4. Rotate the cylinder assembly. Insert the tumbler spring into each of the spring pockets of the cylinder assembly. This side of the cylinder used right tumblers.
5. The first tumbler (3) to be loaded will be the second key cut position, the second number in the key code. Install the first tumbler in the slot over the spring. Install the remaining left tumblers following the key code and same process, pressing the tumblers in place until they are secure.
6. Inspect for correct loading of the tumblers by inserting the key into the cylinder. All tumblers should drop flush with the lock cylinder body diameter.
7. With the key in the cylinder assembly insert the round connector (6), insert the retainer spring (2) in the retainer slot located in the cylinder assembly. Insert the retainer (1) lining it up in the slot over the spring. Depress the retainer and hold.
8. Insert the cylinder into the sleeve (4) as shown in the print. Make sure the actuator stays located properly in the cylinder.
9. When the key is removed, the lock should stay together.
10. Lightly lubricate the outside surface in the tumbler area of in the lock body and down the key slot using the provided grease. Insert and extract the key 5 times to lubricate the keyway.
11. Insert the key and function the lock 3 times to distribute the grease inside the sleeve.
12. Verify the key position for inserting the lock into the column.

Scheme 9

The deck lock cylinder only uses 7 of the 10 cut positions, 4 through 10. The tumbler positions are staggered from side to side, 4 on one side and 3 on the other side. The deck lock cylinder tumblers are self-retaining. After removing the current lock, identify the direction the lever or switch is attached to tail of the lock.

1. Rotate the cylinder (1) so the side with the 4 tumbler spring wells faces up.
2. Insert the tumbler springs (2) into the 4 spring wells.
3. Install the tumbler (3) for key cut position 4 in the slot closest to the cylinder. Install the remaining tumblers, key cut positions 6, 8 and 10, following the key code and same process. Press the tumblers in place until they are secure.
4. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flush with the lock cylinder body.
5. Turn the cylinder so the side with the 3 tumbler spring wells faces up.
6. Insert the tumbler springs into the 3 spring wells.
7. The first tumbler closest to the front of the lock cylinder to be loaded will be the fifth key cut position. Install the remaining tumblers for key cut positions 7 and 9. Press the tumblers in place until they are secure.
8. Check the correct loading of the tumblers by inserting the key into the cylinder. All of the tumblers should be flush with the lock cylinder body.
9. Apply lubricant to the cylinder body and tumbler surfaces along with a small amount in the head of the cylinder using the supplied grease.
10. Install 2 springs (4) into the spring wells in the head of the lock cylinder.
11. Snap the shutter assembly (5) into the cylinder.
12. Assemble the cylinder into the case (6).
13. Align dimples of the cylinder cap (7) with the 4 recesses in the cap. Secure by pressing the cap into place with light hand pressure. If the package contains a switch assembly instead of a lever, assembly switch to back of the lock matching the orientation of the lock removed. Place washer on top of switch and secure with retainer clip (10).
14. If required, assemble the rod clip (9) to the lever (8) using the recorded lever information.
15. Assemble the lever to the lock. Use retainer clip (10) to retain the lever assembly.
16. If supplied, assemble the gasket to the lock.
17. Insert the key into the lock and function the lock to check for proper assembly and smooth operation.

Lifting and Jacking the Vehicle

Note. The use of a LOW PROFILE LIFT ARMS SYSTEM may be required to avoid unwanted contact with the vehicle's body and structure depending on lifting equipment used. Refer to the manufacture's recommendation for their applications of low profile lift arms system for their lifting equipment.

Scheme 10

Vehicle Lifting- Frame Contact Lift

Front Lift Pads

When lifting the vehicle with a frame-contact lift, place the front lift pads on the rocker outer panel weld flange, as shown

Rear Lift Pads

When lifting the vehicle with a frame-contact lift, place the rear lift pads on the rocker outer panel weld flange, as shown.

Vehicle Jacking

Note. When you are lifting a vehicle with a service jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support.

Front of Vehicle

When using a service jack under the front of the vehicle use one of the following locations

Place the service jack pad in the same location as shown for the front lift pads.

Rear of Vehicle

Note. Place jackstands ONLY under strong and stable vehicle structures.

Place the service jack pad in the same location as shown for the rear lift pads.

Special Tools

The special service tools shown in this service manual that have product numbers beginning with J, BO, GE, CH, DT, EN, EL, SA, OR KM are available for worldwide distribution.

US, Canada and Caribbean only

Note. For Special Service tools only - see different location below for diagnostic tools & equipment.

Bosch Automotive Service Solutions

28635 Mound Road

Warren

MI

48092-3499

U.S.A

Phone: 1-800-GM-TOOLS

Monday through Friday

8:00 am-7:00 pm Eastern Standard Time

Fax: 1-800-578-7375 or 586-578-7321

gmspecialservicetools.service-solutions.com

Mexico, Including Central America

Bosch Automotive Service Solutions

Mitla No.442 Col. Vertiz Narvarte

03600 Mexico City

Mexico

Phone: +5255 2595 1630

Fax: +5255 2595 1639

Inquiries can be sent to: herramientas@service-solutions.com

South America, Excluding Brazil

Bosch Automotive Service Solutions

Mitla No.442 Col. Vertiz Narvarte

03600 Mexico City

Mexico

Phone: +5255 2595 1630

Fax: +5255 2595 1639

Inquiries can be sent to: herramientas@service-solutions.com

Brazil

Bosch Automotive Service Solutions

Av. Maria Coelho de Aguiar, 573 - G10

05805-000 Sαo Paulo

Brasil

Phone: +55 11 5851-7477

Fax: +55 11 5853-7479

Inquiries can be sent to: ferramentas@service-solutions.com

Korea, Thailand, Vietnam, Laos, Cambodia

Robert Bosch Korea Ltd, Service Solution

689-17 Geumjeong-dong, Gunpo-si, Gyeonggi-do, 435-862

Korea

Phone: 82-31-457-9520

sales.korea@servicesolutions.com

Fax: 82-31-427-9522

Greater China, SGM,SGMW,FAW-GM, GM OPEL China

Bosch Automotive Service Solutions China

333 Fuquan Road North IBP,Changning District

Shanghai 200335 P.R.

Phone: 86-21-22182668

sales.cn@service-solutions.com

Fax: 0086 21 2218 2677

Australia

Bosch Automotive Service Solutions Australia

300 Wellington Road

Mulgrave

Vic. 3170

Phone: 61 3 9544 6222

Fax: 61 3 9544 5222

Inquiries can be sent to: customerservice.au@service-solutions.com

Iberica S.A.

Dealers based in Spain, Portugal and Canary Islands

Bosch Automotive Service Solutions Europe

Nave 72 (Nudo Oeste), 19004 Guadalajara

Spain

Phone: 34 949 208 337

Fax: 34 949 208 327

shop.service-solutions.com

Europe GmbH

Dealers based in The Netherlands, Belgium and Luxemburg

Bosch Automotive Service Solutions Europe

Albert Tijsstraat 12, 6471 WX Kerkrade

Netherlands

Phone: 31 -45 567 8870

Fax: 31-45 567 8871

shop.service-solutions.com

United Kingdom Limited

Dealers based in UK

Bosch Automotive Service Solutions Europe

Ironstone Way; Brixworth, Northants, NN6 9UD

Great Britain

Phone: 44 -1327 303 400

Fax: 44 -1327 303 499

shop.service-solutions.com

Italy

Dealers based in Italy

Bosch Automotive Service Solutions Europe

Via provinciale, 12, 43038 Sala Baganza-PR

Italy

Phone: 39 -521 837 508

Fax: 39 - 521 335 385

shop.service-solutions.com

Tech 2, MDI Diagnostic Tools and Accessories, Dealer Equipment

US and Canada

Dealer Equipment and Services

5775 Enterprise Drive

Warren

MI, U.S.A

48092-3463

Phone: 1-800-GM-TOOLS

Monday through Friday

8:00 am-6:00 pm EST

Fax: 1-586-578-7205

www.GMDEsolutions.net (US only) or www.des-canada.ca (Canada only)

See also:
• Safety Glasses Warning