GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

The underhood electrical center is part of the forward lamp wiring harness. The underhood electrical center and harness must be replaced as a complete assembly.


    Object Number: 208241  Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

  2. Object Number: 407641  Size: SH
  3. Starting inside the vehicle, disconnect the accel/cruise servo cable adjuster electrical connectors (1).

  4. Object Number: 407643  Size: SH
  5. Disconnect the following connectors from the steering column (1):
  6. • Ignition switch (2)
    • Wiper/washer (3)
    • Remove the insulator from around the connector.
    • Dimmer switch (4)

    Object Number: 407645  Size: SH
  7. Disconnect the electronic throttle control (ETC) electrical connector (1), if equipped with a 3.8L engine.
  8. Disconnect the rosebud clips (2) from the dash mat.
  9. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

  10. Object Number: 407646  Size: SH
  11. Disconnect the secondary air injection (AIR) pump connector (1), if equipped with a 3.8L engine.

  12. Object Number: 282928  Size: SH
  13. Disconnect the vacuum tank hose from the vacuum tank.

  14. Object Number: 407630  Size: SH
  15. Remove the park/turn signal (3) and marker lamp (1) connector from the lamp (2).
  16. On Pontiac, disconnect the side marker lamp connector.

  17. Object Number: 379374  Size: SH
  18. Remove the side repeater lamp (Export only).

  19. Object Number: 407632  Size: SH
  20. Remove the harness clips (1) from the fender rail. (Export only)

  21. Object Number: 407629  Size: SH
  22. Disconnect the connector (1) from the fog lamp (2).
  23. Remove the clip (3) from the front bumper beam.

  24. Object Number: 407626  Size: SH
  25. Remove the secondary lock retainer (3).
  26. Disconnect the headlamp jumper harness (2) from the forward lamp harness (1).

  27. Object Number: 407623  Size: SH
  28. Disconnect the inline headlamp connector (1) from the forward lamp harness.
  29. Disconnect the rosebud clip (5) from the front end panel.
  30. Route the following through the front end panel hole.
  31. • Fog lamp connector (2)
    • Park/turn signal connector (3)
    • Side marker connector (4), Pontiac only
  32. Lower the vehicle.

  33. Object Number: 407647  Size: SH
  34. Remove the captured secondary lock (1) from the connector.
  35. Disconnect the ETC connector (2) from the throttle body, if equipped with a 3.8L engine.

  36. Object Number: 407637  Size: SH
  37. Disconnect the washer pump electrical connector (1).
  38. Disconnect the windshield washer fluid hose (2) from the pump.

  39. Object Number: 407640  Size: SH
  40. Disconnect the forward lamp wiring harness rosebud clips (1) from the tie bar.

  41. Object Number: 407635  Size: SH
  42. Disconnect the cooling fan electrical connectors (1).
  43. Disconnect the harness rosebud clips (2 and 4).
  44. Remove the battery. Refer to Battery Replacement .

  45. Object Number: 407633  Size: SH
  46. Remove the right front ground bolt (2).
  47. Remove the forward lamp wiring ground (3) from the tie bar.
  48. Remove the harness from the outboard of the battery tray (1).
  49. Remove the forward lamp harness headlamp branch through the hole in the front panel.

  50. Object Number: 407622  Size: SH
  51. Remove the forward lamp harness ground stud (1).
  52. Remove the forward lamp harness ground (2).
  53. Disconnect the electronic throttle actuator electrical connector (3), if equipped with a 5.7L engine.

  54. Object Number: 346047  Size: SH
  55. Disconnect the secondary captured locks.
  56. Disconnect the forward lamp harness from the engine harness.
  57. Disconnect the forward lamp harness vacuum tube from the top of the vacuum check valve.

  58. Object Number: 407621  Size: SH
  59. Remove the speed sensor connector (1) from the mid rail.
  60. Disconnect the harness rosebud (2) clip at the coolant fill neck.

  61. Object Number: 211614  Size: SH
  62. Remove the positive battery cable cover.
  63. Remove the positive battery cable nut.
  64. Remove the positive battery cable terminal from the fuseblock.

  65. Object Number: 407616  Size: SH
  66. Remove the ABS/SIR electrical ground stud (1) from the wheelhouse panel.
  67. Remove the ABS/SIR electrical ground terminal (2) from the wheelhouse.

  68. Object Number: 407617  Size: SH
  69. Disconnect the 30 way connector (1) from the brake pressure module valve.

  70. Object Number: 407618  Size: SH
  71. Disconnect the brake fluid level sensor connector (1) from the master cylinder.
  72. Remove the wheel speed sensor connector (2) from the mid rail.

  73. Object Number: 406433  Size: SH
  74. Remove the undehood electrical center from the wheelhouse bracket.
  75. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement in Body Front End.
  76. Disconnect the wiper motor electrical connector.

  77. Object Number: 407620  Size: SH
  78. Remove the wipe motor harness branch from the plenum extension.
  79. Remove the windshield washer fluid hose from the plenum extension.
  80. Remove the forward lamp wiring harness grommet bolt (2).
  81. Remove the harness rosebud clip at the left wheelhouse panel.
  82. Gently, remove the forward lamp harness from inside the vehicle through the front of dash opening.
  83. Remove the forward lamp wiring harness from the vehicle.

Installation Procedure


    Object Number: 407620  Size: SH
  1. Install the forward lamp wiring harness to the vehicle.
  2. Route the forward lamp harness through the front of dash in the interior of the vehicle.
  3. Install the harness rosebud clip to the left wheelhouse panel.
  4. Install the forward lamp wiring harness grommet bolt (2).
  5. Tighten
    Tighten the forward lamp wiring harness grommet bolt (2) to 8 N·m (71 lb in).

  6. Install the windshield washer fluid hose to the plenum extension.
  7. Install the wiper motor branch to the plenum extension.
  8. Connect the wiper motor electrical connector.
  9. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement in Body Front End.

  10. Object Number: 406433  Size: SH
  11. Perform the following to Install the underhood electrical center to the wheelhouse bracket:
  12. 9.1. Tilt the forward lamp harness bracket outboard.
    9.2. Insert the tab on the bracket into the hole in the wheelhouse bracket.
    9.3. Roll bracket back inboard.
    9.4. Secure bracket by sliding down into tabs on tie bar.

    Object Number: 407618  Size: SH
  13. Install the wheel speed sensor connector (2) to the mid rail.
  14. Connect the brake fluid level sensor connector (1) to the master cylinder.

  15. Object Number: 407617  Size: SH
  16. Connect the 30 way connector (1) to the brake pressure module valve.

  17. Object Number: 407616  Size: SH
  18. Install the ABS/SIR electrical ground terminal (2) to the wheelhouse.
  19. Install the ABS/SIR electrical ground stud (1) to the wheelhouse panel.
  20. Tighten
    Tighten the ABS/SIR electrical ground stud (1) to 14 N·m (10 lb ft).


    Object Number: 407614  Size: SH
  21. Install the harness ground wire (2) to the tie bar.
  22. Install the left front forward lamp wiring ground bolt (1).
  23. Tighten
    Tighten the left front forward lamp wiring ground bolt (1) to 10 N·m (89 lb in).


    Object Number: 211614  Size: SH
  24. Install the positive battery cable terminal to the fuseblock.
  25. Install the positive battery cable nut.
  26. Tighten
    Tighten the positive battery cable nut to 14 N·m (10 lb ft).

  27. Install the positive battery cable cover.

  28. Object Number: 407621  Size: SH
  29. Connect the harness rosebud (2) clip to the coolant fill neck.
  30. Install the speed sensor connector (1) to the mid rail.

  31. Object Number: 346047  Size: SH
  32. Connect the forward lamp harness vacuum tube to the top of the vacuum check valve.
  33. Connect the forward lamp harness to the engine harness.
  34. Connect the secondary captured locks.

  35. Object Number: 407622  Size: SH
  36. Connect the electronic throttle actuator electrical connector (3), if equipped with a 5.7L engine.
  37. Install the forward lamp harness ground (2).
  38. Install the forward lamp harness ground stud (1).
  39. Tighten
    Tighten the forward lamp harness ground stud (1) to 16 N·m (12 lb ft).


    Object Number: 407633  Size: SH
  40. Route the forward lamp harness headlamp branch through the hole in the front panel.
  41. Tuck the harness into the opening forward of the battery tray (1).
  42. Install the forward lamp wiring ground (3) to the tie bar.
  43. Install the right front ground bolt (2).
  44. Tighten
    Tighten the right front ground bolt (2) to 10 N·m (89 lb in).

  45. Install the battery. Refer to Battery Replacement .

  46. Object Number: 407635  Size: SH
  47. Connect the rosebud clips (2 and 4).
  48. Connect the cooling fan electrical connectors (1).

  49. Object Number: 407640  Size: SH
  50. Connect the forward lamp wiring harness rosebud clips (1) to the tie bar.

  51. Object Number: 407637  Size: SH
  52. Connect the windshield washer fluid hose (2) to the pump.
  53. Connect the washer pump electrical connector (1).

  54. Object Number: 407647  Size: SH
  55. Connect the ETC connector (2) to the throttle body, if equipped with 3.8L engine.
  56. Install the captured secondary lock (1) to the connector.
  57. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

  58. Object Number: 407623  Size: SH
  59. Route the following through the front end panel hole:
  60. • Side marker connector (4), Pontiac only
    • Park/turn signal connector (3)
    • Fog lamp connector (2)
  61. Connect the rosebud clip (5) to the front end panel.
  62. Connect the inline headlamp connector (1) to the forward lamp harness.

  63. Object Number: 407626  Size: SH
  64. Connect the headlamp jumper harness (2) to the forward lamp harness (1).
  65. Install the secondary lock retainer (3).

  66. Object Number: 407629  Size: SH
  67. Install the clip (3) to the front bumper beam.
  68. Connect the fog lamp connector (2) to the lamp.

  69. Object Number: 407632  Size: SH
  70. Install the harness clips (1) to the fender rail. (Export only)

  71. Object Number: 379374  Size: SH
  72. Install the side repeater lamp. (Export only)

  73. Object Number: 407630  Size: SH
  74. Install the park/turn signal (3) and marker (1) connector to the lamp (2).
  75. On Pontiac, connect the side marker lamp connector.

  76. Object Number: 282928  Size: SH
  77. Connect the vacuum tank hose to the vacuum tank.

  78. Object Number: 407646  Size: SH
  79. Connect the AIR pump connector (1), if equipped with a 3.8L engine.
  80. Lower the vehicle.

  81. Object Number: 407645  Size: SH
  82. Connect the rosebud clips (2) to the dash mat.
  83. Connect the ETC electrical connector (1), if equipped with a 3.8L engine.

  84. Object Number: 407643  Size: SH
  85. Connect the following connector to the steering column (1):
  86. • Dimmer switch (4)
    • Wiper/washer (3)
    • Install the insulator around the connector.
    • Ignition switch (2)

    Object Number: 407641  Size: SH
  87. Connect the accel/cruise servo cable adjuster electrical connectors (1).

  88. Object Number: 208241  Size: SH
  89. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .