Service Procedure

Caution:
This procedure requires the vehicle coolant temperature to be below normal operating temperature. For technician safety the coolant temperature should be below 100 °F (3B °C) before starting the repair.

If the coolant Is at normal operating temperature when you perform this service, you could be burned. To reduce the risk of injury1 do not start this procedure until the vehicle coolant has cooled to 100 °F (38 ° C,).

1. Install seat and fender covers.

2. Recover the air conditioning system using published procedures from the 1999 Electronic Service Information.

While the air conditioning system is being recovered, perform the following steps:

^ Remove the rear seat cushion and place on a clean surface with the springs down. Cover the seat cushion to protect it from foreign contamination.

^ Disconnect the negative battery cable from the battery.

^ Disable the Supplemental Restraint System (SRS) using published procedures from 1999 Service Information.

^ Remove the filler panel. on top of the radiator support.

3. Remove radiator cap from the surge tank.

4. Raise and suitably support the vehicle.

5. Drain the engine coolant into a clean container by removing the coolant hose from the generator coolant tube. Save the coolant for reuse. Leave the hose disconnected.

6. Lower the vehicle.

7. Disconnect the electrical connector from the ambient air temperature sensor.

8. Remove the primary hood latch from the support, disconnect the release cable. and set aside.

9, Remove the hood latch support.

10. Remove both headlamps, disconnecting the wiring at the inline connector.

11. Disconnect the air conditioning lines from the condenser. Seal the lines to avoid possible contamination of the air conditioning system. Discard the sealing washers.

12. Remove the radiator retaining bolts and brackets.

13. Remove the upper coolant hose from the radiator and place over the top of the engine.

14. Disconnect the driver's side radiator side shield from the radiator support.

15. Remove transaxle cooler line bracket bolt.

18. Tip the top of the condenser1 radiator. fan shroud and cooling fan assembly toward the front of the vehicle.

17. Disconnect the upper transaxie cooler line from the radiator.

18. Remove lower radiator hose from the radiator.

19. Disconnect the lower transaxie cooler line from the radiator.

20. Open the retainer holding the A/C line to the fan shroud end position the line out of the retainer.

21. Disconnect the electrical connectors from the coolant fans.

22. Remove the condenser, radiator. fan shroud and cooling fan assembly from the vehicle.

23. Remove the coolant tube and bracket bolt end remove the coolant tube and bracket from the generator.

24. Remove electrical connections from the generator.

25. Remove the accessory drive belt from the generator pulley.

26. Remove the generator attaching bolts and remove the generator.

27. Transfer the coolant hose from the old generator to the new generator.

28. Install new generator P/N 10464396 on the vehicle and tighten bolts to 47 N.m (35 lb ft).

NOTICE:
Secure the ground wire when installing mounting bolts.

29. Install the accessory drive belt on the generator pulley and inspect for proper belt alignment on all of the pulleys.

30. Install electrical connections to the generator.

Notice:
When attaching the battery positive (B+) cable to the generator stud:

The insulating rubber boot must be completely clear of the stud when the attaching nut 18 installed and tightened.

^ Make sure the nut is properly tightened to 13 N.m (10 lb ft) and that no part of the rubber boot is caught under the nut.

^ Make sure the insulating rubber boot is properly placed over the battery positive cable connection to the generator.

31. Install the coolant tube and bracket to the generator.

32. Position the condenser, radiator, fan shroud and cooling fan assembly to the vehicle. Make sure the coolant fan electrical connector and hood release cable are accessible.

33. Connect the electrical connectors to the coolant fans.

34. Place the A/C line in the retainer on the fan shroud and lock the retainer.

35. Connect the lower transaxle cooler line to the radiator.

36. Connect the lower radiator hose to the radiator.

37. Connect the upper transaxle cooler line to the radiator.

38. Properly position the radiator in the vehicle.

39. Install transaxle cooler line bracket bolt.

40. Reposition radiator side shield to the radiator support and install retainers.

41. Install upper radiator hose to the radiator and properly position.

42. Install radiator retaining brackets and bolts.

43. Clean and wash hands.

44. Insert 1/4 oz. of R134A tracer dye P/N 12348303 (or Kent Moore # J-41447) into the top A/C line at the condenser using Kent Moore tool # J-41436.

45. Clean the interface on the condenser and the air conditioning lines of any foreign material with a lint free rag.

46. Install new sealing washers P/N 52474373 to the air conditioning lines. Install the lines to the condenser assembly. Tighten nuts to 20 N.m (15 lb ft).

47. Remove any refrigerant residue from the condenser-to-air conditioning line Joints by spraying with engine degreaser P/N 01050436.

48. Connect the wiring for the headlamps and install the headlamps.

49. Install the hood latch support. Tighten the bolts to 9 N.m (80 lb in).

50. Install the hood release cable into the primary hood latch bracket, and hook up to the hood latch. Install the bolts which retain the hood latch to the bracket. Tighten the bolts to 9 N.m (80 lb in).

51. Connect the electrical connector to the ambient air temperature sensor.

52. Raise and suitably support the vehicle.

53. Install the coolant hose from the radiator to the generator coolant tube.

54. Lower the vehicle.

55. Recharge the air conditioning system. While waiting for the system to recharge perform the following.

^ Connect the negative battery cable to the battery.

^ Properly install the rear seat cushion. Make sure the Beet belts are properly positioned.

^ Enable the supplemental restraint system, using service procedures from the 1999 Electronic Service information.

56. Start end run the engine with the air conditioning in the maximum position.

Using J 28428-E high intensity black light, check for leaks at the air conditioning interfaces which were opened for this repair. Correct as required.

57. install the filler panel over the top of the radiator.

58. Check transaxie oil for proper fill. Add transaxle oil P/N 12346145 as required.

59. Check engine coolant fluid level for proper fill. Add engine coolant P/N 12377963 as required.

60. Remove the seat and fender covers.

61. Install the GM Campaign Identification Label.