Dangers, Warnings, and Cautions

‌INTRODUCTION

GENERAL INFORMATION

Dangers, Warnings, and Cautions - Volt

DEFINITION OF DANGER, WARNING, CAUTION, AND NOTE

The diagnosis and repair procedures in a GM Service Manual contain both general and specific Dangers, Warnings, Cautions, Notes or 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. Dangers, Warnings, Cautions and Notes or 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 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

ABS COMPONENT HANDLING WARNING

WARNING: 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.

ACTIONS TO TAKE WHEN WORKING WITH FUEL WARNING

WARNING: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors:

Use forced air ventilation such as a fan set outside of the trunk.

Plug or cap any fuel system openings in order to reduce fuel vapor formation.

Clean up any spilled fuel immediately.

Avoid sparks and any source of ignition.

Use signs to alert others in the work area that fuel system work is in process.

APPROVED EQUIPMENT FOR COLLISION REPAIR WARNING

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. In addition when grinding aluminum components, always use an extraction system to remove high dust concentration due to risk of explosion.

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.

BATTERY DISCONNECT WARNING

WARNING: Unless directed otherwise, the ignition must be OFF with the key removed, 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 OnStarÂ® (UE1) with Back Up Battery:

The Back Up Battery is a redundant power supply to allow limited OnStarÂ® functionality in the event of a main vehicle battery power disruption to the VCIM (OnStarÂ®module). Do not disconnect the main vehicle battery or remove the OnStarÂ® fuse with the ignition key in any position other than OFF. Retained accessory power should be allowed to time out or be disabled (simply opening the driver door should disable retained accessory power) before disconnecting power. Disconnecting power to the OnStarÂ® module in any way while the ignition is On or with retained accessory power activated may cause activation of the OnStarÂ® Back-Up Battery 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 back-up battery is not rechargeable and once activated the back-up battery 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.

BRAKE FLUID IRRITANT WARNING

WARNING: 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.

CHECKING HOT TRANSMISSION FLUID THROUGH DRAIN PLUG HOLE WARNING

WARNING: 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.

CLEANING SOLVENT WARNING

WARNING: Bodily injury may occur if the cleaning solvent is inhaled or exposed to the skin.

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.

CRACKED WINDOW WARNING

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.

DIESEL/GASOLINE VAPORS WARNING

WARNING: Fuel/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.

EXHAUST SERVICE WARNING

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.

EXPRESS WINDOW DOWN WARNING

WARNING: Disconnect the power window switch when working inside the 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.

FOAM SOUND DEADENERS WARNING

WARNING: 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 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 115Â°C (239Â°F) for more than one hour, or more than 90Â°C (194Â°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 GAUGE LEAK WARNING

WARNING: 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 gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete.

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. This will ensure proper reconnection and prevent a possible fuel leak. Always replace O-rings.

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.

FUEL VAPORS IN EVAPORATIVE EMISSION COMPONENTS WARNING

WARNING: Do not breathe the air through the EVAP component tubes or hoses. The fuel vapors inside the EVAP components may cause personal injury.

GLASS AND SHEET METAL HANDLING WARNING

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.

HOOD HOLD-OPEN DEVICE WARNING

WARNING: 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 WARNING

WARNING: While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.

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.

PROTECTIVE GOGGLES AND GLOVE WARNING

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.

RELIEVING FUEL PRESSURE WARNING

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.

ROAD TEST WARNING

WARNING: 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 AND COMPRESSED AIR WARNING

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.

SAFETY GOGGLES AND FUEL WARNING

WARNING: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

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 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 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 appropriate country, regional or local laws.

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 SPECIAL TOOL WARNING

WARNING: Failure to observe the special tool recommendations and instructions could

cause SIR deployment, personal injury, or unnecessary SIR system repairs.

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 Master Electrical Components List 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. Refer to Disabling the SIR System.

STEERING ANGLE SENSOR INITIALIZATION WARNING

WARNING: For vehicles with electric power steering (EPS) and without a vehicle stability enhancement program, the steering angle sensor MUST always be initialized after the battery has been disconnected. Failure to initialize the steering angle sensor could limit the operation of the EPS system and result in personal injury.

To ensure proper initialization of the EPS system, do the following:

1. The engine should be on with the vehicle stationary.

2. Turn the steering wheel counterclockwise until it stops.

3. Turn the steering wheel clockwise until it stops.

TORQUE-TO-YIELD FASTENER WARNING

WARNING: This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fasteners could cause damage to the vehicle, component, or bodily injury.

TRANSMISSION SHIFT CONTROL WARNING

WARNING: After installing the transmission range selector shift cable, pull up and push down on ALL connections to verify that the connections are fully seated and properly engaged. Failure to perform this task can result in the vehicle not being able to shift into PARK causing potential vehicle damage and bodily injury.

WINDOW RETENTION WARNING

WARNING: When replacing stationary windows, only use a single component adhesive kit, or an adhesive system meeting GM Specifications, to maintain original installation integrity. Failure to use the single component 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 WARNING

WARNING: 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.

When running an engine in the work stall, use the exhaust removal system to prevent breathing dangerous gases.

AIR IN THE POWER STEERING SYSTEM CAUTION

CAUTION: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time.

AVOID CHIPPING OR SCRATCHING THE COATING CAUTION

CAUTION: 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.

BALL STUD REMOVAL CAUTION

CAUTION: Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or bushing may result.

BATTERY ENERGY CONTROL MODULE CONNECTOR CAUTION

CAUTION: The battery energy control modules internal cell balancing circuitry is powered by the cell group voltage sense circuits. In order to prevent an unrecoverable, unbalanced Hybrid/EV battery section or internal control module damage, always take the following actions:

1. Disconnect ALL of the battery energy control module connectors prior to disconnecting any Hybrid/EV battery section connector.

2. Reconnect all the Hybrid/EV battery section connectors prior to reconnecting the battery energy control module connectors.

3. Disconnect and reconnect the battery energy control module connectors ONLY in the sequence provided in Repair Instructions.

BELT DRESSING CAUTION

CAUTION: 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 CALIPER CAUTION

CAUTION: Support the caliper with a piece of wire to prevent damage to the brake line.

BRAKE FLUID EFFECTS ON PAINT AND ELECTRICAL COMPONENTS CAUTION

CAUTION: 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.

CLEAN, DRY, LOW PRESSURE GAS SOURCE CAUTION

CAUTION: Use the Evaporative Emission (EVAP) System Tester GE 41413-A in order to provide a clean, dry, low pressure nitrogen gas source. Do not substitute any other pressurized source, gas or otherwise. Damage may result to the EVAP system, test equipment or cause a safety risk.

CLEARCOAT/ULTRAVIOLET SCREENERS CAUTION

CAUTION: 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.

COLLISION REPAIR ANCHORING CAUTION

CAUTION: Proper anchoring of the vehicle is required before pulling on the vehicle structure. The vehicle must be properly anchored at all four corners of the passenger compartment, to keep the HV battery pack from being damaged during the repair. Removal of the HV battery pack is recommended, if the vehicle can not be properly anchored.

COMPONENT FASTENER TIGHTENING CAUTION

CAUTION: 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.

CRANKSHAFT POSITION SENSOR RELUCTOR RING CAUTION

CAUTION: Do not allow the crankshaft position sensor reluctor ring to come into contact with external magnetic fields or sharp metal objects. Do not drop the crankshaft position sensor reluctor ring. Do not damage the rubberized encoder track.

Failure to follow these precautions may cause damage to the component.

DRIVE AXLE CAUTION

CAUTION: Support the lower control arms in the normal horizontal position in order to avoid damage to the drive axles. Do not operate the vehicle in gear with the wheels hanging down at full travel.

ENGINE COOLANT THERMOSTAT HOUSING CAUTION

CAUTION: Use care when performing this procedure. Use of excessive force may damage the coolant thermostat.

EXTERIOR TRIM EMBLEM REMOVAL CAUTION

CAUTION: Use a plastic, flat-bladed tool to prevent paint damage when removing an emblem/name plate.

FASTENER CAUTION

CAUTION: 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.

FUEL AND EVAPORATIVE EMISSION HOSE/PIPE CONNECTION CLEANING CAUTION

CAUTION: 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

HEATED OXYGEN AND OXYGEN SENSOR CAUTION

CAUTION: 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 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 an appropriate 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 RESISTANCE LEARN RESET CAUTION

CAUTION: When replacing the HO2S perform the following:

A code clear with a scan tool, regardless of whether or not a DTC is set HO2S heater resistance learn reset with a scan tool, where available

Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure.

HVAC MODULE DRAIN TUBE CAUTION

CAUTION: Always ensure the HVAC module drain tube is properly installed and secure following a repair. Residual moisture/water can collect inside the HVAC module. The residual moisture or water should not contact electrical modules, electrical connections, wiring, cables or carpeting. Use clean and absorbent shop clothes to protect these components while removing or installing the HVAC module drain tube and/or HVAC module. Moisture/water is a by-product of normal A/C system operation and can result in interior odors or corrosion/damage to electrical components.

INSTALLING HOSES WITHOUT TWISTS OR BENDS CAUTION

CAUTION: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage.

PAINT DAMAGE CAUTION

CAUTION: To avoid paint damage, protect the area surrounding the part which you are removing or installing.

PIPE WRENCH POSITIONING CAUTION

CAUTION: 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 CAUTION

CAUTION: 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.

RETAINING RING REUSE CAUTION

CAUTION: Do not reuse the retaining ring. Install a NEW retaining ring. Reusing the old retaining ring may cause damage to the clutch assembly.

SEALANT CAUTION

CAUTION: 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.

SEAL REUSE CAUTION

CAUTION: Do not reuse the seals. Replace with NEW seals. Reusing old seals may cause transmission damage.

SILICON CONTAMINATION OF HEATED OXYGEN SENSORS CAUTION

CAUTION: 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 COLUMN IN LOCK POSITION CAUTION

CAUTION: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components:

The steering column

The steering shaft coupling The intermediate shaft(s)

After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil.

STEERING GEAR PRELOAD ADJUSTMENT CAUTION

CAUTION: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod could result in damage to the pinion and the steering gear.

STEERING WHEEL IN THE FULL TURN POSITION CAUTION

CAUTION: 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 CAUTION

The steering column

The intermediate shaft(s) The steering gear

TAPE CORNERS OF PANEL CAUTION

CAUTION: When removing body panels, apply tape to corners of panel and adjacent surfaces to help prevent paint damage.

TEST PROBE CAUTION

CAUTION: Do not insert test equipment probes (DMM 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 EL-35616 GM Approved Terminal Test Probe Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals.

When using the EL-35616 GM Approved Terminal Test Probe 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 EL-35616 GM Approved Terminal Test Probe Kit label on the inside of the EL-35616 GM Approved Terminal Test Probe Kit for the correct adapter along with the connector end view.

THREE-WAY CATALYTIC CONVERTER DAMAGE CAUTION

CAUTION: 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.

TORQUE REACTION AGAINST TIMING DRIVE CHAIN CAUTION

CAUTION: 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.

TORQUE-TO-YIELD FASTENER CAUTION

CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

TRANSMISSION FLUID VENT CAP REMOVAL CAUTION

CAUTION: The fluid vent cap must be removed before checking the fluid level, in order to ensure the proper level. Improper fluid level may damage the transmission.

TRANSMISSION OVERFILL CAUTION

CAUTION: Check the transmission fluid level immediately after adding fluid and before vehicle operation. Do not overfill the transmission. An overfilled transmission may result in foaming or fluid to be expelled out the vent tube when the vehicle is operated. Overfilling will result in possible damage to the transmission.

USING PROPER POWER STEERING FLUID CAUTION

CAUTION: When adding fluid or making a complete fluid change, always use the proper

power steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks.

VALVE LIFTER PRIMING CAUTION

CAUTION: 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 CAUTION

CAUTION: 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.

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