Danger
| WARNING | In order to reduce the chance of death, personal injury and/or property damage, carefully observe the instructions that follow: The service manuals of General Motors are intended for use by professional, qualified technicians. Attempting repairs or service without the appropriate training, tools, and equipment could cause death or injury to you or others. This could also damage the vehicle, or cause the vehicle to operate improperly. Proper vehicle service and repair are important to the safety of the service technician and to the safe, reliable operation of all motor vehicles. If you need to replace a part, use the same part number or an equivalent part. Do not use a replacement part of lesser quality. The service procedures we recommend and describe in this service manual are effective methods of performing service and repair. Some of the procedures require the use of tools that are designed for specific purposes. Accordingly, any person who intends to use a replacement part, a service procedure, or a tool that is not recommended by General Motors, must first establish that there is no jeopardy to personal safety or the safe operation of the vehicle. This manual contains various "Dangers", "Warnings" and "Cautions" that you must observe carefully in order to reduce the risk of personal injury during service or repair. Improper service or repair may damage the vehicle or render the vehicle unsafe. These "Dangers", "Warnings" and "Cautions" are not exhaustive. General Motors can not possibly warn of all the potentially hazardous consequences of your failure to follow these instructions. |
Definition of Danger, Warning, Caution, and Note
- Serious bodily injury or death to the technician
- Damage to the vehicle
- Unnecessary vehicle repairs
- Unnecessary component replacement
- Improper repair or replacement of vehicle components.
- Any warning or caution that appears in this service category is referenced from the individual service categories.
DANGER Defined
When encountering a DANGER, you will be asked to take a necessary action or not to take a prohibited action. If a DANGER is not heeded, the following consequences may occur
- Serious bodily injury or death to the technician
- Serious bodily injury or death to other technicians in the workplace area
WARNING Defined
When encountering a WARNING, you will be asked to take a necessary action or not to take a prohibited action. If a WARNING 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
CAUTION Defined
CAUTIONS call special attention to a necessary action or to a prohibited action. If a CAUTION 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
NOTE or IMPORTANT Defined
NOTE and IMPORTANT statements emphasize a necessary characteristic of a diagnostic or repair procedure. NOTE or 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
Warning: Approved equipment for collision repair
| WARNING | 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 Warning
| WARNING | An assistant should drive the vehicle while the technician checks for the location of the reported condition. Otherwise, personal injury could result. |
Warning: Disconnecting battery
| WARNING | Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. For Vehicles equipped with OnStar® (UE1) with Back Up Battery: The Back Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar®module). Do not disconnect the main vehicle battery or remove the OnStar® fuse with the ignition key in any position other than OFF. Retained accessory power supply shall time out or be deactivated (if the driver door is opened, RAP-power is deactivated before the power is disconnected. Disconnecting power to the OnStar® module in any way while the ignition is On or with RAP activated may cause activation of the OnStar® Back-Up Battery (BUB) system and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will stay on until it has completely discharged. The BUB is not rechargeable and once activated the BUB must be replaced. |
Brake Dust Warning
| WARNING | 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. |
Collision Sectioning Warning
| WARNING | 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. |
Warning: Cracked window
| WARNING | If a window is cracked but still intact, crisscross the window with masking tape in order to reduce the risk of damage or personal injury. |
Defroster Outlet Warning
| WARNING | If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury. |
Warning: Removing differential case
| WARNING | To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case. |
Warning: Servicing exhaust system
| WARNING | In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. |
Warning: Window function Express Down
| WARNING | 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 Warning
| WARNING | Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. |
Fuel and Evaporative Emission Pipe Warning
| WARNING | 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 Pipe Fitting Warning
| WARNING | 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. |
Warning: Installing fuel rail stop bracket
| WARNING | 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 and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire and personal injury from burns. |
Fuel Storage Warning
| WARNING | 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. |
Gasoline/Gasoline Vapors Warning
| WARNING | 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. |
Warning: Handling glass and sheet metal
| WARNING | 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 Warning
| WARNING | 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. |
Warning: Hot exhaust system
| WARNING | While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system. |
Warning: Removing tailgate hydraulic system
| WARNING | When a tailgate hydraulic system component is removed, installed or disconnected, provide alternate support to avoid the possibility of damage to the vehicle, tailgate hydraulic system, or personal injury. |
Moving Parts and Hot Surfaces Warning
| WARNING | Avoid contact with moving parts and hot surfaces while working around a running engine in order to prevent physical injury. |
Warning: Wear protective goggles and gloves
| WARNING | 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. |
Warning: Relieving fuel pressure
| WARNING | 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. |
Warning: Use safety glasses when working with compressed air
| WARNING | Wear safety glasses when using compressed air in order to prevent eye injury. |
Safety Glasses Warning
| WARNING | Wear safety glasses in order to avoid eye damage. |
Warning: Stitching by installed side airbag
| WARNING | Do not repair or replace the seat stitching or seams in the seat back trim cover with an internal mounted seat side airbag module. Replace the complete seat back trim cover from the OEM. Non-OEM seat stitching may cause improper airbag deployment which could result in personal injury. |
Servicing the SIR System Warning
| WARNING | Take actions in the list below for service on or around the SIR-components or SIR-cables 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 Inflator Module Coil Warning
| WARNING | 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 Inflator Module Handling and Storage Warning
| WARNING | 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 Seatbelt Pretensioner Handling Warning
| WARNING | When carrying an undeployed inflatable restraint seat belt retractor pretensioner: Do not carry the seat belt pretensioner by the seat belt webbing or pigtail connector, if equipped. Carry the seat belt pretensioner by the housing, keeping hands and fingers away from the seat belt webbing. Make sure the opening, from which the seat belt webbing extends, faces downward and the seat belt webbing hangs freely. Failure to observe these guidelines may result in personal injury. |
SIR Inflatable Module Deployment Outside Vehicle Warning
| WARNING | When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. |
SIR Deployed Inflator Modules Are Hot Warning
| WARNING | 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 Inflator Module Disposal Warning
| WARNING | 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 Warning
| WARNING | This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions: Air bag deployment Personal injury Unnecessary SIR system repairs In order to avoid the above conditions, observe the following guidelines: Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring. If you are performing service on or near the SIR components or the SIR-wiring, disable the SIR-system. See the section on how to disable the SIR-system. See SIR SERVICE PRECAUTIONS . |
Valve Springs Can Be Tightly Compressed Warning
| WARNING | Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. |
Warning: Window retention
| WARNING | 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. |
Caution: Belt dressing
| WARNING | 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. |
Caution: The fuel tank shall be clean, dry, and have low pressure
| WARNING | Use the EVAP Pressure/Purge Diagnostic Station CH 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. |
Caution: Clearcoat/Ultraviolet screeners
| WARNING | Removing more than 0.5 mils of the clearcoat can result in early paint failure. The clearcoat contains ultraviolet screeners. Do not grind more than what is needed to remove the defect. |
Caution: Damage to fuel tank straps
| WARNING | Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps. |
| WARNING | Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps. |
Caution: Removing differential housing cover and gasket
| WARNING | 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. |
Caution: Excessive force and oxygen sensor
| WARNING | 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. |
Caution: Retainer
| WARNING | Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. 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. When using fasteners that are threaded directly into plastic, use extreme care not to strip the mating plastic part(s). Use hand tools only, and do not use any kind of impact or power tools. Fastener should be hand tightened, fully seated, and not stripped. |
Caution: Cleaning connection fuel and evaporative emission hose/pipe
| WARNING | 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 |
Caution: Handling parts sensitive to electrostatic discharge
| WARNING | Electrostatic discharge (ESD) can damage many solid-state electronic semi-conductor components. Components sensitive to ESD may sometimes be marked 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. |
Heated Oxygen and Oxygen Sensor Caution
| WARNING | Do not remove the 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 are not 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 wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. 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. |
Caution: Tailgate assist rod
| WARNING | 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 Caution
| WARNING | Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to the machined surface can cause leakage. |
Caution: Hose for power steering disconnected
| WARNING | 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. |
Caution: Removing ring gear
| WARNING | 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. |
Caution: Surface Sealant
| WARNING | 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. |
Caution: Silicon contamination of heated oxygen sensors
| WARNING | 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. |
Steering Wheel in the Full Turn Position Caution
| WARNING | Do not hold the steering wheel in the full turn position longer than 5 seconds, as damage to the steering pump may result. |
Caution: Damage to three-way catalytic converter
| WARNING | In order to avoid damaging the replacement three-way catalytic converter, correct the engine misfire or mechanical fault before replacing the three-way catalytic converter. |
Caution: Removing transfer case seal
| WARNING | 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. |
Caution: Valve lifter, priming
| WARNING | 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 valve lifter's high-pressure chamber is not purged, which may cause extensive damage to engine components. |
| WARNING | When you are deploying an inflator module for disposal, perform the deployment procedures in the order listed. Failure to follow the procedures in the order listed may result in personal injury. |
