SMU - SECTION 6D3 - REVISED GENERATOR SERVICE PROCEDURE. Chevrolet Lumina 1996

REVISION: 09/17/96

THIS BULLETIN IS BEING REVISED TO DELETE STEPS 7 & 8 (REMOVE OR DISCONNECT) AND STEPS 11 & 12 (INSTALL OR CONNECT) SHOWN IN THE ORIGINAL BULLETIN. ALSO, REFERENCE TO 1997 VEHICLES IN SEVERAL OF THE STEPS WAS DELETED. ----------------------------------------------------------------------

REVISION: 10/25/96

THIS BULLETIN IS BEING REVISED TO ADD WARRANTY INFORMATION. THIS BULLETIN ALSO CANCELS AND SUPERSEDES CORPORATE BULLETIN NUMBER 336404. PLEASE DISCARD CORPORATE BULLETIN NUMBERS 336404 AND 636407 (SECTION 6 - ENGINE). ----------------------------------------------------------------------

SUBJECT: SERVICE MANUAL UPDATE - SECTION 6D3 - REVISED GENERATOR SERVICE PROCEDURE

MODELS: 1991-96 CHEVROLET LUMINA 1995-96 CHEVROLET MONTE CARLO 1991-96 PONTIAC GRAND PRIX 1991-96 OLDSMOBILE CUTLASS SUPREME WITH 3.4L DOHC V6 ENGINE (VIN X - RPO LQ1)

THIS BULLETIN IS BEING ISSUED TO REVISE THE PREVIOUS GENERATOR SERVICE PROCEDURE IN SECTION 6D3 OF THE SERVICE MANUAL. THE REVISED PROCEDURE DELETES THE NEED TO REMOVE THE DRIVE AXLE AND GENERATOR SPLASH SHIELD. INSTEAD, THE INTERMEDIATE STEERING SHAFT LOWER PINCH BOLT IS REMOVED. THEN THE INTERMEDIATE SHAFT IS SEPARATED FROM THE STEERING GEAR. A JACKING FIXTURE IS INSTALLED TO SUPPORT THE REAR OF THE FRAME. THE TWO REAR FRAME BOLTS ARE REMOVED AND THE FRAME IS THEN LOWERED NO MORE THAN 100 MM (4 IN.), GAINING ACCESS TO THE GENERATOR.

REFER TO THE PROPER VEHICLE SERVICE MANUAL AND OTHER SERVICE BULLETINS FOR SPECIFIC SUB-COMPONENT REMOVAL, INSTALLATION AND TIGHTENING SPECIFICATIONS.

PROCEDURE:

REMOVE OR DISCONNECT

1. BATTERY NEGATIVE CABLE FROM THE BATTERY NEGATIVE TERMINAL. REFER TO SECTION 6D1 OF THE SERVICE MANUAL.

2. IGNITION CONTROL MODULE WITH MOUNTING BRACKET AND POSITION FORWARD FOR CLEARANCE ON 1996 VEHICLES. REFER TO ENGINE CONTROLS OR SECTION 6E3 OF THE SERVICE MANUAL.

3. BOTH FRONT WHEELS. REFER TO SECTION 3E OF THE SERVICE MANUAL.

4. RIGHT ENGINE SPLASH SHIELD. REFER TO SECTION 4D OF THE SERVICE MANUAL.

5. INTERMEDIATE SHAFT LOWER PINCH BOLT AND INTERMEDIATE SHAFT FROM STEERING GEAR. REFER TO SECTION 3B OF THE SERVICE MANUAL.

CAUTION:

FAILURE TO DISCONNECT THE INTERMEDIATE SHAFT FROM THE RACK AND PINION STUB SHAFT CAN RESULT IN DAMAGE TO THE STEERING SHAFT AND/OR INTERMEDIATE SHAFT. THIS DAMAGE CAN CAUSE LOSS OF STEERING CONTROL WHICH COULD RESULT IN PERSONAL INJURY.

6. RAISE VEHICLE AND SUITABLY SUPPORT. REFER TO SECTION 0A OF THE SERVICE MANUAL.

7. INSTALL A JACKING FIXTURE TO SUPPORT THE REAR OF THE FRAME.

8. FRAME REAR BOLTS. REFER TO SECTION 10-3 OF THE SERVICE MANUAL.

9. USING THE JACKING FIXTURE, LOWER THE REAR OF THE FRAME.

NOTICE: DO NOT LOWER THE FRAME MORE THAN 100 MM (4 IN.) OR DAMAGE TO THE VEHICLE'S COMPONENTS MAY RESULT.

10. GENERATOR COOLING DUCT.

11. ELECTRICAL CONNECTOR AT GENERATOR.

12. GENERATOR "BAT" TERMINAL NUT AND LEAD FROM GENERATOR.

13. ACCESSORY DRIVE BELT FROM GENERATOR. REFER TO ENGINE MECHANICAL OR SECTION 6A9A OF THE SERVICE MANUAL.

14. GENERATOR REAR BRACE.

15. POWER STEERING GEAR PIPE CLIP FROM GENERATOR STUD (IF APPLICABLE). REFER TO SECTION 3B OF THE SERVICE MANUAL.

16. GENERATOR TO ENGINE FASTENERS.

17. GENERATOR.

INSTALL OR CONNECT

1. GENERATOR.

2. GENERATOR TO ENGINE FASTENERS.

3. GENERATOR REAR BRACE.

4. POWER STEERING GEAR PIPE CLIP TO GENERATOR STUD (IF APPLICABLE). REFER TO SECTION 3B OF THE SERVICE MANUAL.

5. ACCESSORY DRIVE BELT TO GENERATOR. REFER TO ENGINE MECHANICAL OR SECTION 6A9A OF THE SERVICE MANUAL.

6. GENERATOR "BAT" TERMINAL LEAD AND NUT TO GENERATOR.

7. ELECTRICAL CONNECTOR TO GENERATOR.

8. GENERATOR COOLING DUCT.

9. USING THE JACKING FIXTURE, RAISE THE FRAME REAR UNTIL THE FRAME INSULATORS CONTACT THE VEHICLE BODY.

10. NEW FRAME REAR BOLTS. REFER TO SECTION 10-3 OF THE SERVICE MANUAL.

11. INTERMEDIATE SHAFT TO STEERING GEAR AND LOWER PINCH BOLT. REFER TO SECTION 3B OF THE SERVICE MANUAL.

12. RIGHT ENGINE SPLASH SHIELD. REFER TO SECTION 4D OF THE SERVICE MANUAL.

13. BOTH FRONT WHEELS. REFER TO SECTION 3E OF THE SERVICE MANUAL.

14. LOWER THE VEHICLE.

15. IGNITION CONTROL MODULE WITH MOUNTING BRACKET ON 1996 VEHICLES. REFER TO ENGINE CONTROLS OR SECTION 6E3 OF THE SERVICE MANUAL.

16. BATTERY NEGATIVE CABLE TO THE BATTERY NEGATIVE TERMINAL. REFER TO SECTION 6D1 OF THE SERVICE MANUAL.

WARRANTY INFORMATION:

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

LABOR OPERATION LABOR OPERATION NUMBER DESCRIPTION TIME =============== =========== ===============

J4100 GENERATOR ASSEMBLY - 1.4 HR REPLACE

ADD: DIAGNOSIS 0.3 HR

ADD: LOCKING WHEEL COVERS/ 0.1 HR NUTS (ONE OR ALL)

FIGURES: 00 ATTACHMENTS: 00

GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS AND KNOW-HOW TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE A GENERAL MOTORS DEALER SERVICING YOUR BRAND OF GENERAL MOTORS VEHICLE FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.