Definition of Caution, Notice, and Important
The diagnosis and repair procedures in the GM Service Manual contain both general and specific Cautions, Notices, and Importants. GM is dedicated to the presentation of service information that helps the technician to diagnose and 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, and 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 repairs
- 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 Antilock 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 and installation procedures should be serviced. |
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, and 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 and thoroughly. Get medical help. |
Battery Disconnect Caution
| CAUTION | Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and 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 and skin. In case of contact, take the following actions: Eye contact-rinse thoroughly with water. Skin contact-wash with soap and water. If ingested-consult a physician immediately. |
Breathing R-134a Caution
| CAUTION | Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and 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 and safety information may be obtained from the refrigerant and lubricant manufacturers. |
Camshaft Holding Tool Caution
| CAUTION | The camshaft holding tools must be installed on the camshafts to prevent camshaft rotation. When performing service to the valve train and/or timing components, valve spring pressure can cause the camshafts to rotate unexpectedly and can cause personal injury. |
Checking Hot Transmission Fluid through Drain Plug Hole Caution
| CAUTION | The engine must be running when the transmission fluid fill plug is removed, or excessive fluid loss will occur. Transmission fluid may be hot. Since the actual fluid level is unknown, stand clear when removing the fill plug. Have a container ready to capture any lost fluid. Do not turn the engine off with the fill plug removed, as you can be injured by hot transmission fluid being expelled out of the oil fill opening. |
Collision Sectioning Caution
| CAUTION | Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision. |
Compressed Valve Spring Caution
| CAUTION | Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. |
Electric Coolant Fan Caution
| CAUTION | An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan. |
Exhaust Service Caution
| CAUTION | In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. |
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 and gloves should be worn when performing this procedure to reduce the chance of personal injury. |
Failure to Prep Primer Caution
| CAUTION | Failure to prep the area prior to the application of primer may cause insufficient bonding of urethane adhesive. Insufficient bonding of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in 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. |
Fuel and EVAP Pipe Caution
| CAUTION | In order to reduce the risk of fire and 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 and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and 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 and 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 and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. |
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 and Sheet Metal Handling Caution
| CAUTION | When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and 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 and 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 and 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 and 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 and Hot Surfaces Caution
| CAUTION | Avoid contact with moving parts and hot surfaces while working around a running engine in order to prevent physical injury. |
Protective Goggles and Glove Caution
| CAUTION | Always wear protective goggles and gloves when removing exhaust parts as falling rust and 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 and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. |
Relieving Fuel Pressure Caution
| CAUTION | Remove the fuel tank cap and 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. |
Road Test Caution
| CAUTION | Road test a vehicle under safe conditions and 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 and vehicle damage. |
Safety Glasses Caution
| CAUTION | Wear safety glasses in order to avoid eye damage. |
Safety Glasses and Compressed Air Caution
| CAUTION | Wear safety glasses when using compressed air in order to prevent eye injury. |
Safety Goggles and Fuel Caution
| CAUTION | Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash. |
SIR Seatbelt Pretensioner Handling Caution
| CAUTION | When you are carrying an undeployed seat belt pretensioner: Do not carry the seat belt pretensioner by the wires or connector on the pretensioner. Do not touch the seat belt pretensioner in the area of the cable (1). Do not cover the tube opening with your hand. Keep the open end of the tube pointed away from you. Do not point the open end of the tube at another person. When the pretensioner deploys the cable retracts. This shortens the pretensioner between the buckle and the mounting bolt. Grasp the pretensioner by the piston tube (2). Disregarding these precautions may result in personal injury or unnecessary 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 and 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 Dual Stage Inflator Module Handling Caution
| CAUTION | A deployed dual stage inflator module will look the same whether one or both stages were used. Always assume a deployed dual stage inflator module has an active stage 2. Improper handling or servicing can activate the inflator module and cause personal injury. |
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 and the risk of personal injury, do not dispose of an undeployed inflator module 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 and 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 and the column vertical. Lay the column on its side. Failure to observe these guidelines may result in personal injury. |
SIR Side Impact Sensor Handling Caution
| CAUTION | Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. |
SIR Special Tool Caution
| CAUTION | Failure to observe the special tool recommendations and instructions could cause SIR deployment, personal injury, or unnecessary SIR system repairs. |
Vehicle Lifting Caution
| CAUTION | To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and 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 GM3651G, 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 and 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 and the transmission. When a test requires jacking up the vehicle and running with the wheels and 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. |
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.
Avoid Chipping or Scratching the Coating Notice
Note. Care should be taken to avoid chipping or scratching the coating when handling the suspension coil spring. Damage to the coating can cause premature failure.
Avoid Damage to Grid Lines Notice
Note. If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result.
Ball Stud Removal Notice
Note. Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or bushing may result.
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 Fluid Effects on Paint and Electrical Components Notice
Note. Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and 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.
Catalytic Converter Movement Notice
Note. To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.
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.
Connector Test Adapter Kit J 35616-A Notice
Note. Use the connector test adapter kit J 35616-A for any test that requires probing the following items: The PCM harness connectors The electrical center fuse/relay cavities The component terminals The component harness connector Using this kit will prevent damage caused by the improper probing of connector terminals.
Constant Velocity Joint Seal Damage Notice
Note. Do not cut through the wheel drive shaft inboard seal during service. Cutting through the seal may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.
Disengaging Connectors Notice
Note. DO NOT use any mechanical device such as pliers or screwdrivers to disengage the connector. In order to prevent damage to the connector or harness wiring, both of the latches on the connector must be depressed with finger pressure only. When the latches are depressed the connector must then be pulled straight back without pulling on the wires in order to disengage. Failure to follow this procedure can lead to connector or wiring harness damage and failure.
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 and 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 and 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.
Excessive Force and 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 and possible damage to the passenger compartment insulation and 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 and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Fastener Retainer Usage Notice
Note. If the retainer is used to assist the reassembly of the component, do NOT allow the retainer to interfere with the sealing or the mating surfaces. An interfering retainer can cause improper tightening and clamp loads, which could damage the component.
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 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 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 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 and 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 and 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 and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and 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 and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and 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 and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed.
Heated Oxygen Sensor (HO2S) Wire Repair Notice
Note. Do not solder heated oxygen sensor wires. Soldering the wires will result in the loss of the air reference to the sensor. Refer to Engine Electrical for proper wire and connection repair techniques.
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.
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.
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.
OBD II 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 and 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 and 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.
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 and damage to the system.
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 and 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 and the terminal cable connections must be secure. A battery charger must NOT be connected to the battery when programming a control module.
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 and 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 and possible engine damage, relieve the fuel pressure before performing the fuel injector coil test procedure.
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.
Steering Wheel Straight and Column Locked Notice
Note. The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become uncentered which will cause damage to the coil assembly.
Tape Corners of Panel Notice
Note. When removing body panels, apply tape to corners of panel and adjacent surfaces to help prevent paint damage.
Test Probe Notice
Note. Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size.
Torque Reaction Against Timing Drive Chain Notice
Note. A wrench must be used on the hex of the camshaft when loosening or tightening in order to prevent component damage. Failure to prevent the torque reaction against the timing drive chain can lead to timing drive chain failure.
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.
Window Edge Damage Notice
Note. Avoid damage to the window from impacting objects due to an exposed edge. The window must be 1 mm (0.025 in) below the surface of the sheet metal to avoid window damage.
