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‌SPECIFICATIONS

FASTENER SPECIFICATIONS

ACCESSORIES & EQUIPMENT

Frame and Underbody - Volt

Single Use Threaded Fastener/Component Tightening Specifications

Reusable Threaded Fastener Tightening Specifications

REPAIR INSTRUCTIONS

FRONT COMPARTMENT SPLASH SHIELD REPLACEMENT

Fig. 1: Front Compartment Splash Shield Courtesy of GENERAL MOTORS COMPANY

FRONT COMPARTMENT AIR DEFLECTOR REPLACEMENT

Fig. 2: Front Compartment Air Deflector Courtesy of GENERAL MOTORS COMPANY

FRONT UNDERBODY AIR DEFLECTOR REPLACEMENT

Fig. 3: Front Underbody Air Deflector Courtesy of GENERAL MOTORS COMPANY

UNDERBODY FRONT AIR DEFLECTOR REPLACEMENT - LEFT SIDE

Fig. 4: Underbody Front Air Deflector - Left Side Courtesy of GENERAL MOTORS COMPANY

UNDERBODY FRONT AIR DEFLECTOR REPLACEMENT - RIGHT SIDE

Fig. 5: Underbody Front Air Deflector - Right Side Courtesy of GENERAL MOTORS COMPANY

UNDERBODY REAR AIR DEFLECTOR REPLACEMENT

Fig. 6: Underbody Rear Air Deflector

Courtesy of GENERAL MOTORS COMPANY

DRIVETRAIN AND FRONT SUSPENSION CROSSMEMBER EXTENSION REPLACEMENT

Special Tools

EN-45059 Angle Meter

Equivalent regional tools:Special Tools

Removal Procedure

1. Support the radiator using mechanics wire.

2. Remove the drivetrain and front suspension cradle. Drivetrain and Front Suspension Cradle Replacement

3. Remove the front underbody air deflector. Front Underbody Air Deflector Replacement

Fig. 7: Generator Control Module Coolant Pump Bracket And Nuts Courtesy of GENERAL MOTORS COMPANY

4. Remove the generator control module coolant pump bracket (1) from the drivetrain and front suspension cross member extension. Generator Control Module Coolant Pump Replacement

Fig. 8: Hose Clamps And Retainer

Courtesy of GENERAL MOTORS COMPANY

5. Remove the hose clamps (1, 4).

6. Disconnect the hose (2) from the clamps (3).

7. Disconnect the retainer (5) from the drivetrain and front suspension cross member extension.

Fig. 9: Heater Coolant Heater And Bolts Courtesy of GENERAL MOTORS COMPANY

8. Remove the heater coolant heater bolts (1).

9. Support the heater coolant heater (2) with a strap or mechanics wire.

10. Disconnect all wiring harness retainers from the drivetrain and front suspension cross member extension.

11. Support the drivetrain and front suspension cross member extension using a suitable jack.

Fig. 10: Front Suspension Cross Member Extension Bolts Courtesy of GENERAL MOTORS COMPANY

12. Remove and DISCARD the drivetrain and front suspension cross member extension bolts (1).

Fig. 11: Drivetrain And Front Suspension Cross Member Extension Courtesy of GENERAL MOTORS COMPANY

13. Lower the drivetrain and front suspension cross member extension (1).

Installation Procedure

Fig. 12: Drivetrain And Front Suspension Cross Member Extension Courtesy of GENERAL MOTORS COMPANY

1. Raise the drivetrain and front suspension cross member extension (1) into position.

2. Connect all wiring harness retainers to the drivetrain and front suspension cross member extension.

Fig. 13: Heater Coolant Heater And Bolts Courtesy of GENERAL MOTORS COMPANY

CAUTION: Fastener Caution

3. Install the heater coolant heater bolts (1) and tighten to 9 N.m (80 lb in).

4. Remove the strap or mechanics wire from the heater coolant heater.

Fig. 14: Generator Control Module Coolant Pump Bracket And Nuts Courtesy of GENERAL MOTORS COMPANY

5. Install the generator control module coolant pump bracket (1) to the drivetrain and front suspension cross member extension. Generator Control Module Coolant Pump Replacement

Fig. 15: Hose Clamps And Retainer

Courtesy of GENERAL MOTORS COMPANY

6. Install the hose clamps (1, 4).

7. Connect the hose (2) to the clamps (3).

8. Connect the retainer (5) from the drivetrain and front suspension cross member extension.

9. Loosely install the NEW drivetrain and front suspension cross member extension bolts to support the cradle extension.

10. Install the drivetrain and front suspension cradle. Drivetrain and Front Suspension Cradle Replacement

11. Remove the jack supporting the drivetrain and front suspension cross member extension.

Fig. 16: Front Suspension Cross Member Extension Bolts Courtesy of GENERAL MOTORS COMPANY

WARNING: Torque-to-Yield Fastener Warning CAUTION: Fastener Caution

12. Tighten the NEW drivetrain and front suspension cross member extension bolts (1) as follows:

Tighten:

1. First Pass: 100 N.m (74 lb ft)

2. Final Pass: 45 - 60 degrees use the EN-45059 meter

13. Install the front underbody air deflector. Front Underbody Air Deflector Replacement

14. Lower the vehicle. Lifting and Jacking the Vehicle

15. Remove mechanics wire from the radiator.

DRIVETRAIN AND FRONT SUSPENSION CRADLE REPLACEMENT

Special Tools

EN-45059 Angle Meter

CH-51034 - A Cradle Alignment Pins

Equivalent regional tools:Special Tools

Removal Procedure

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 intermediate shaft(s) The steering gear

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.

CAUTION: Electrostatic discharge (ESD) can damage many solid-state electrical components. ESD susceptible components may or may not be labeled 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.

NOTE: Vehicle alignment is not required if the cradle is being lowered or dropped to perform another procedure. This vehicle is equipped with a cradle to body aligning feature: cradle to body through holes or self-aligning pins that are part of the cradle or body. Only align if replacing the cradle with a NEW part and transferring components.

1. Disable the high voltage system. High Voltage Disabling

2. Disconnect the steering intermediate shaft from the steering gear. Intermediate Steering Shaft Replacement

3. Remove the front tire and wheel assemblies. Tire and Wheel Removal and Installation

4. Remove Front Wheelhouse Liner Front Wheelhouse Liner Replacement (Left Side)Front Wheelhouse Liner Replacement (Right Side)

5. Remove Front Underbody Air Deflector Front Underbody Air Deflector Replacement

Fig. 17: Radiator Air Side Baffle Bolt And Radiator Air Lower Baffle Bracket Courtesy of GENERAL MOTORS COMPANY

6. Remove Radiator Air Side Baffle Bolt (1) @Radiator Air Lower Baffle Bracket (2)

Fig. 18: Drivetrain And Front Suspension Crossmember Extension Fasteners Courtesy of GENERAL MOTORS COMPANY

7. Loosen Drivetrain and Front Suspension Cradle Extension Bolt (3)

Fig. 19: Heater Water Bypass Valve Bracket Bolt And Heater Water Bypass Valve Bracket Courtesy of GENERAL MOTORS COMPANY

8. Remove Heater Water Bypass Valve Bracket Bolt (1) @Heater Water Bypass Valve Bracket (2)

Fig. 20: Drivetrain And Front Suspension Cradle, Brace And Bolt Courtesy of GENERAL MOTORS COMPANY

9. Remove the drivetrain and front suspension brace (2) from the drivetrain and front suspension cradle (1).

10. Remove Exhaust Muffler Exhaust Muffler Replacement

Fig. 21: Stabilizer Shaft Link, Stabilizer Shaft And Nut Courtesy of GENERAL MOTORS COMPANY

NOTE: Hold against the hex of the threaded stud to release the nuts. Use a suitable tool.

NOTE: Support the front suspension with a hydraulic jack to disconnect the stabilizer shaft links.

11. Remove Stabilizer Shaft Link Nut (2)

12. Disconnect Stabilizer Shaft Link (1) @Stabilizer Shaft (3)

Fig. 22: Steering Knuckle, Lower Ball Joint And Nut Courtesy of GENERAL MOTORS COMPANY

NOTE: Support the front suspension under the front lower control arm ball joint with a hydraulic jack to release the nut.

13. Remove Lower Ball Joint Nut (1)

14. Separate the steering knuckle (2) from the lower ball joint stud (3).

15. Disconnect the outer tie rod from the steering knuckle.Steering Linkage Outer Tie Rod Replacement

Fig. 23: Transmission Mount Strut Bolt And Transmission Mount Strut Courtesy of GENERAL MOTORS COMPANY

16. Remove Transmission Mount Strut Bolt (1) @Transmission Mount Strut (2) and DISCARD

Fig. 24: Drivetrain And Front Suspension Cradle Supported With Suitable Hydraulic Jack Courtesy of GENERAL MOTORS COMPANY

17. Support the drivetrain and front suspension cradle (1) with a suitable hydraulic jack (2).

18. Wiring Harness@Drivetrain and Front Suspension Cradle - Disconnect as necessary

19. Wiring Harness@Electric Belt Drive Rack and Pinion Steering Gear - Disconnect as necessary

Fig. 25: Drivetrain And Front Suspension Crossmember Extension Fasteners Courtesy of GENERAL MOTORS COMPANY

20. Loosen the Drivetrain and Front Suspension Cradle (2) and Drivetrain and Front Suspension Cradle Extension bolts (3) and lower both cradle and extension until the 4 bolts (2) which attach the Drivetrain and Front Suspension Cradle to the Drivetrain and Front Suspension Cradle Extension can be removed.

NOTE: Note: Drivetrain and Front Suspension Cradle Extension removal is not required for Drivetrain and Front Suspension Cradle replacement.

21. Remove and DISCARD Drivetrain and Front Suspension Cradle to Drivetrain and Front Suspension

Cradle Extension bolts (2) and nuts (1).

Fig. 26: Drivetrain And Front Suspension Cradle Bolts Courtesy of GENERAL MOTORS COMPANY

22. Remove and DISCARD the drivetrain and front cradle bolts (2).

23. Carefully lower the drivetrain and front suspension cradle as far as necessary to disconnect the wiring harness.

Fig. 27: Power Steering Assist Motor And Electrical Connectors Courtesy of GENERAL MOTORS COMPANY

NOTE: Wiring harness routing is critical. Note the exact routing of the steering gear wiring harness before repositioning it.

24. Disconnect Electrical Connector (1) @Power Steering Assist Motor (2)

25. Disconnect Electrical Connector (3) @Power Steering Assist Motor (2)

Fig. 28: Electric Belt Drive Rack And Pinion Steering Gear, Bolts, Nuts And Washers Courtesy of GENERAL MOTORS COMPANY

NOTE: If the steering gear bolts are not removed, the vehicle sheet metal could become distorted.

26. Remove the left 2 of the 3 steering gear bolts (4) and nuts (1) and DISCARD the bolts and nuts. Loosen the third bolt on the right, so the steering gear (3) can be pivoted forward as the cradle is lowered. This will allow the steering gear input shaft to clear the hole in the floor as the Drivetrain and Front Suspension Cradle is lowered.

NOTE: Continue to carefully lower the drivetrain and front suspension cradle, pivoting the steering gear, moving rearward and downward until the drivetrain and front suspension cradle is clear of the drivetrain and front suspension cradle extension.

27. Carefully lower the drivetrain and front suspension cradle.

Fig. 29: Stabilizer Shaft And Bolts

Courtesy of GENERAL MOTORS COMPANY

28. Remove Stabilizer Shaft Bracket Bolt (1) and DISCARD

29. Remove Stabilizer Shaft (2)

Fig. 30: Steering Gear Bolt And Electric Belt Drive Rack and Pinion Steering Gear Courtesy of GENERAL MOTORS COMPANY

30. Remove Steering Gear Bolt (4) @ Electric Belt Drive Rack and Pinion Steering Gear (3) and DISCARD

31. Remove Steering Gear Nut (1) @Electric Belt Drive Rack and Pinion Steering Gear (3)

32. Remove the 3 washers (2) from the electric belt drive rack and pinion steering gear.

33. Remove Electric Belt Drive Rack and Pinion Steering Gear (3)

Fig. 31: Front Lower Control Arm, Bushing Bolts And Nuts

Courtesy of GENERAL MOTORS COMPANY

34. Remove Front Lower Control Arm Bushing Bolt (1) and DISCARD

35. Remove Front Lower Control Arm Rear Bushing Bolt (3) and DISCARD

36. Remove Front Lower Control Arm Rear Bushing Nut (2) and DISCARD

37. Remove Front Lower Control Arm (4)

Fig. 32: Transmission Mount Strut And Bolt Courtesy of GENERAL MOTORS COMPANY

38. Remove Transmission Mount Strut Bolt (2) and DISCARD

39. Remove Transmission Mount Strut (1)

40. Transfer components as necessary.

Installation Procedure

Fig. 33: Transmission Mount Strut And Bolt Courtesy of GENERAL MOTORS COMPANY

1. Install Transmission Mount Strut (1)

WARNING: Torque-to-Yield Fastener Warning CAUTION: Fastener Caution

2. Install New Transmission Mount Strut Bolt (2)Transmission Mount Strut Replacement

Fig. 34: Front Lower Control Arm, Bushing Bolts And Nuts Courtesy of GENERAL MOTORS COMPANY

3. Install Front Lower Control Arm (4)

WARNING: Torque-to-Yield Fastener Warning

4. Install New Front Lower Control Arm Rear Bushing Bolt (3)Lower Control Arm Replacement

5. Install New Front Lower Control Arm Rear Bushing Nut (2)Lower Control Arm Replacement

WARNING: Torque-to-Yield Fastener Warning

6. Install New Front Lower Control Arm Bushing Bolt (1)Lower Control Arm Replacement

Fig. 35: Steering Gear Bolt And Electric Belt Drive Rack and Pinion Steering Gear Courtesy of GENERAL MOTORS COMPANY

NOTE: Install one new bolt (4), washer (2) and nut (1) loosely, on the right side to allow steering gear to pivot on cradle during drivetrain and front suspension cradle installation.

7. Install Electric Belt Drive Rack and Pinion Steering Gear ((3)

8. Install the 1 washer (2) to the electric belt drive rack and pinion steering gear.

9. Install Steering Gear Nut (1) @Electric Belt Drive Rack and Pinion Steering Gear

10. Install Steering Gear Bolt(4) @Electric Belt Drive Rack and Pinion Steering Gear (3)Electric Belt Drive Rack and Pinion Steering Gear Replacement

Fig. 36: Stabilizer Shaft And Bolts

Courtesy of GENERAL MOTORS COMPANY

11. Install Stabilizer Shaft (2)

12. Install Stabilizer Shaft Bracket Bolt (1) and tighten the NEW bolt.Stabilizer Shaft Replacement

Fig. 37: Steering Column Dash Outer Seal Courtesy of GENERAL MOTORS COMPANY

13. Make sure the notch in the steering column dash outer seal (1) is still correctly aligned to the nose on the electric belt drive rack and pinion steering gear.

NOTE: Pivot the electric belt drive rack and pinion steering forward as the drivetrain and front suspension cradle is being raised up to the vehicle. Insert the front horns of the drivetrain and front suspension cradle into the drivetrain and front suspension cradle extension as the drivetrain and front suspension cradle gets closer to the body. Once the drivetrain and front suspension cradle is inserted into the drivetrain and front suspension cradle extension, pivot the steering gear rearward so steering shaft goes up into the floor as the cradle is raised up to the vehicle.

14. Raise the drivetrain and front suspension cradle to the vehicle.

Fig. 38: Drivetrain And Front Suspension Crossmember Extension Fasteners Courtesy of GENERAL MOTORS COMPANY

15. Install New Insert NEW Drivetrain and Front Suspension Crossmember Extension Rear Bolt (2)

16. Install New Drivetrain and Front Suspension Cradle Nut (1)

Fig. 39: Electric Belt Drive Rack And Pinion Steering Gear, Bolts, Nuts And Washers Courtesy of GENERAL MOTORS COMPANY

17. Install the two washers (2) to the electric belt drive rack and pinion steering gear.

18. Install the remaining steering gear bolts (4), washers (2) and nuts (1). Electric Belt Drive Rack and Pinion Steering Gear Replacement

Fig. 40: Power Steering Assist Motor And Electrical Connectors Courtesy of GENERAL MOTORS COMPANY

19. Connect Electrical Connector(1)@Power Steering Assist Motor(2)

20. Connect Electrical Connector(3) @Power Steering Assist Motor (2)

Fig. 41: Drivetrain And Front Suspension Cradle And Alignment Pins Courtesy of GENERAL MOTORS COMPANY

21. Install the 2 CH-51034 - A Cradle Alignment Pins (1, 3) to arrange the drivetrain and front suspension cradle during tightening.

22. Make sure that the drivetrain and front suspension cradle (2) fits closely to the vehicle.

23. Make sure that the 2 CH-51034 - A Cradle Alignment Pins fit closely to the drivetrain and front suspension cradle (2).

Fig. 42: Steering Column Dash Outer Seal, Electric Belt Drive Rack And Pinion Steering Gear Courtesy of GENERAL MOTORS COMPANY

24. Make sure the steering column dash outer seal (3) fits correctly on the electric belt drive rack and pinion steering gear (2). See arrows.

25. Make sure the steering column dash outer seal (3) fits correctly on the dash panel front lower cross bar

(1). See arrows.

26. Wiring Harness@Drivetrain and Front Suspension Cradle - Connect as necessary

27. Wiring Harness@Electric Belt Drive Rack and Pinion Steering Gear - Connect as necessary

Fig. 43: Transmission Mount Strut Bolt And Transmission Mount Strut Courtesy of GENERAL MOTORS COMPANY

28. Install New Transmission Mount Strut Bolt(1)@Transmission Mount Strut(2) - Do NOT tighten. -

Transmission Mount Strut Replacement

Fig. 44: Drivetrain And Front Suspension Cradle Bolts Courtesy of GENERAL MOTORS COMPANY

WARNING: Torque-to-Yield Fastener Warning

29. Install New Drivetrain and Front Suspension Cradle Bolt (2).

Tighten:

1. First Pass:70 N.m (52 lb ft)

2. Final Pass:45 - 60 degrees, use the EN-45059 meter

Fig. 45: Drivetrain And Front Suspension Crossmember Extension Fasteners Courtesy of GENERAL MOTORS COMPANY

WARNING: Torque-to-Yield Fastener Warning

30. Install New Drivetrain and Front Suspension Crossmember Extension Rear Bolt (2).Drivetrain and Front Suspension Crossmember Extension Replacement

31. Install New Drivetrain and Front Suspension Crossmember Extension Bolt (3).Drivetrain and Front Suspension Crossmember Extension Replacement

32. Install New Drivetrain and Front Suspension Cradle Nut (1).

Tighten

1. First Pass:100 N.m (74 lb ft)

2. Final Pass: 45 - 60 Degrees, use the EN-45059 Angle Meter

Fig. 46: Transmission Mount Strut Bolt And Transmission Mount Strut Courtesy of GENERAL MOTORS COMPANY

WARNING: Torque-to-Yield Fastener Warning

33. Install New Transmission Mount Strut Bolt(1) @Transmission Mount Strut(2)Transmission Mount Strut Replacement

Fig. 47: Stabilizer Shaft Link, Stabilizer Shaft And Nut

Courtesy of GENERAL MOTORS COMPANY

NOTE: Hold against the hex of the threaded stud to tighten the nuts. Use a suitable tool.

NOTE: Support the front suspension with a hydraulic jack to connect the stabilizer shaft links.

34. Connect Stabilizer Shaft Link(1)@Stabilizer Shaft(3)

35. Install Stabilizer Shaft Link Nut(2)@Stabilizer Shaft Link(1) and tighten the nut - Stabilizer Shaft Replacement

36. Connect the outer tie rod to the steering knuckle Steering Linkage Outer Tie Rod Replacement

Fig. 48: Steering Knuckle, Lower Ball Joint And Nut Courtesy of GENERAL MOTORS COMPANY

NOTE: Support the lower control arm under the ball joint with a hydraulic jack to tighten the nut.

37. Install the lower ball joint stud (3) to the steering knuckle (2).

WARNING: Torque-to-Yield Fastener Warning

38. Install Lower Ball Joint Nut (1)Lower Control Arm Replacement

Fig. 49: Radiator Air Side Baffle Bolt And Radiator Air Lower Baffle Bracket Courtesy of GENERAL MOTORS COMPANY

39. Install Radiator Air Side Baffle Bolt (1) @Radiator Air Lower Baffle Bracket (2) and tighten Radiator Air Lower Baffle and Deflector Replacement

Fig. 50: Heater Water Bypass Valve Bracket Bolt And Heater Water Bypass Valve Bracket Courtesy of GENERAL MOTORS COMPANY

40. Install Heater Water Bypass Valve Bracket Bolt (1) @Heater Water Bypass Valve Bracket (2) and tighten

- Heater Water Shutoff Valve Replacement

41. Install Exhaust Muffler Exhaust Muffler Replacement

Fig. 51: Drivetrain And Front Suspension Cradle, Brace And Bolt Courtesy of GENERAL MOTORS COMPANY

42. Install the drivetrain and front suspension brace (2) to the drivetrain and front suspension cradle (1).

43. Install Drivetrain and Front Suspension Cradle Bolt (3) and tighten 58 N.m (43 lb ft)

44. Install Front Underbody Air Deflector Front Underbody Air Deflector Replacement

45. Install Front Wheelhouse Liner Front Wheelhouse Liner Replacement (Left Side)Front Wheelhouse Liner Replacement (Right Side)

46. Install the front tire and wheel assemblies. Tire and Wheel Removal and Installation

47. Connect the steering intermediate shaft to the steering gear. Intermediate Steering Shaft Replacement

48. Enable the high voltage system. High Voltage Enabling

49. Check the steering wheel angle sensor centering. Steering Wheel Angle Sensor Centering

50. If the drivetrain and front suspension cradle was replaced with a NEW cradle, perform a wheel alignment.

Wheel Alignment Measurement

DRIVETRAIN AND FRONT SUSPENSION CRADLE REMOVAL AND INSTALLATION

Special Tools

EN-45059 Angle Meter

CH-51034 - A Cradle Alignment Pins

Equivalent regional tools:Special Tools

Removal Procedure

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 intermediate shaft(s) The steering gear

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.

CAUTION: Electrostatic discharge (ESD) can damage many solid-state electrical components. ESD susceptible components may or may not be labeled 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.

NOTE: Vehicle alignment is not required if cradle is being lowered or dropped to perform another procedure. This vehicle is equipped with a cradle to body aligning feature: cradle to body through holes or self-aligning pins that are part of cradle or body. Only align if replacing the cradle with NEW part and transferring components.

1. Disable the high voltage system. High Voltage Disabling

2. Disconnect the steering intermediate shaft from the steering gear. Intermediate Steering Shaft

Replacement

3. Remove the front tire and wheel assemblies. Tire and Wheel Removal and Installation

4. Remove Front Wheelhouse Liner Front Wheelhouse Liner Replacement (Left Side)Front Wheelhouse Liner Replacement (Right Side)

5. Remove Front Underbody Air Deflector Front Underbody Air Deflector Replacement

Fig. 52: Radiator Air Side Baffle Bolt And Radiator Air Lower Baffle Bracket Courtesy of GENERAL MOTORS COMPANY

6. Remove Radiator Air Side Baffle Bolt (1) @Radiator Air Lower Baffle Bracket (2)

Fig. 53: Drivetrain And Front Suspension Crossmember Extension Fasteners Courtesy of GENERAL MOTORS COMPANY

7. Loosen Drivetrain and Front Suspension Cradle Extension Bolt (3)

Fig. 54: Heater Water Bypass Valve Bracket Bolt And Heater Water Bypass Valve Bracket Courtesy of GENERAL MOTORS COMPANY

8. Heater Water Bypass Valve Bracket Bolt (1) @Heater Water Bypass Valve Bracket (2)

Fig. 55: Drivetrain And Front Suspension Cradle, Brace And Bolt Courtesy of GENERAL MOTORS COMPANY

9. Remove the drivetrain and front suspension brace (2) from the drivetrain and front suspension cradle (1).

10. Remove Exhaust Muffler Exhaust Muffler Replacement

Fig. 56: Stabilizer Shaft Link, Stabilizer Shaft And Nut Courtesy of GENERAL MOTORS COMPANY

NOTE: Hold against the hex of the threaded stud to release the nuts. Use a suitable tool.

NOTE: Support the front suspension with a hydraulic jack to disconnect the stabilizer shaft links.

11. Remove Stabilizer Shaft Link Nut (2)

12. Disconnect Stabilizer Shaft Link (1) @Stabilizer Shaft(3)

Fig. 57: Steering Knuckle, Lower Ball Joint And Nut Courtesy of GENERAL MOTORS COMPANY

NOTE: Support the front suspension under the front lower control arm ball joint with a hydraulic jack to release the nut.

13. Remove Lower Ball Joint Nut (1)

14. Separate the steering knuckle (2) from the lower ball joint stud (3).

15. Disconnect the outer tie rod from the steering knuckle.Steering Linkage Outer Tie Rod Replacement

Fig. 58: Transmission Mount Strut Bolt And Transmission Mount Strut Courtesy of GENERAL MOTORS COMPANY

16. Remove Transmission Mount Strut Bolt (1) @Transmission Mount Strut (2) and DISCARD

Fig. 59: Drivetrain And Front Suspension Cradle Supported With Suitable Hydraulic Jack Courtesy of GENERAL MOTORS COMPANY

17. Support the drivetrain and front suspension cradle (1) with a suitable hydraulic jack (2).

18. Wiring Harness@Drivetrain and Front Suspension Cradle - Disconnect as necessary

19. Wiring Harness@Electric Belt Drive Rack and Pinion Steering Gear - Disconnect as necessary

Fig. 60: Drivetrain And Front Suspension Crossmember Extension Fasteners Courtesy of GENERAL MOTORS COMPANY

20. Loosen the Drivetrain and Front Suspension Cradle (2) and Drivetrain and Front Suspension Cradle Extension bolts (3) and lower both cradle and extension until the 4 bolts (2) which attach the Drivetrain and Front Suspension Cradle to the Drivetrain and Front Suspension Cradle Extension can be removed.

NOTE: Note: Drivetrain and Front Suspension Cradle Extension removal is not required for Drivetrain and Front Suspension Cradle replacement.

21. Remove and DISCARD Drivetrain and Front Suspension Cradle to Drivetrain and Front Suspension Cradle Extension bolts (2) and nuts (1).

Fig. 61: Drivetrain And Front Suspension Cradle Bolts Courtesy of GENERAL MOTORS COMPANY

22. Remove and DISCARD the drivetrain and front cradle bolts (2).

23. Carefully lower the drivetrain and front suspension cradle as far as necessary to disconnect the wiring

harness.

Fig. 62: Power Steering Assist Motor And Electrical Connectors Courtesy of GENERAL MOTORS COMPANY

NOTE: Wiring harness routing is critical. Note the exact routing of the steering gear wiring harness before repositioning it.

24. Disconnect Electrical Connector(1)@Power Steering Assist Motor (2)

25. Disconnect Electrical Connector (3) @Power Steering Assist Motor (2)

Fig. 63: Electric Belt Drive Rack And Pinion Steering Gear, Bolts, Nuts And Washers Courtesy of GENERAL MOTORS COMPANY

NOTE: If the steering gear bolts are not removed, the vehicle sheet metal could become distorted.

26. Remove the left 2 of the 3 steering gear bolts (4) and nuts (1) and DISCARD the bolts and nuts. Loosen

the third bolt on the right, so the steering gear (3) can be pivoted forward as the cradle is lowered. This will allow the steering gear input shaft to clear the hole in the floor as the Drivetrain and Front Suspension Cradle is lowered.

NOTE: Continue to carefully lower the drivetrain and front suspension cradle, pivoting the steering gear, moving rearward and downward until the drivetrain and front suspension cradle is clear of the drivetrain and front suspension cradle extension.

27. Carefully lower the drivetrain and front suspension cradle.

Fig. 64: Stabilizer Shaft And Bolts

Courtesy of GENERAL MOTORS COMPANY

28. Remove Stabilizer Shaft Bracket Bolt (1) and DISCARD

29. Remove Stabilizer Shaft (2)

Fig. 65: Steering Gear Bolt And Electric Belt Drive Rack and Pinion Steering Gear Courtesy of GENERAL MOTORS COMPANY

30. Remove Steering Gear Bolt (4) @Electric Belt Drive Rack and Pinion Steering Gear(3) and DISCARD

31. Remove Steering Gear Nut(1)@Electric Belt Drive Rack and Pinion Steering Gear(3)

32. Remove the 3 washers (2) from the electric belt drive rack and pinion steering gear.

33. Remove Electric Belt Drive Rack and Pinion Steering Gear(3)

Fig. 66: Transmission Mount Strut And Bolt Courtesy of GENERAL MOTORS COMPANY

34. Remove Transmission Mount Strut Bolt (2) and DISCARD

35. Remove Transmission Mount Strut (1)

Installation Procedure

Fig. 67: Transmission Mount Strut And Bolt Courtesy of GENERAL MOTORS COMPANY

1. Install Transmission Mount Strut (1)

WARNING: Torque-to-Yield Fastener Warning CAUTION: Fastener Caution

2. Install New Transmission Mount Strut Bolt (2)Transmission Mount Strut Replacement

Fig. 68: Steering Gear Bolt And Electric Belt Drive Rack and Pinion Steering Gear Courtesy of GENERAL MOTORS COMPANY

NOTE: Install one new bolt (4), washer (2) and nut (1) loosely, on the right side to allow steering gear to pivot on cradle during drivetrain and front suspension cradle installation.

3. Install Electric Belt Drive Rack and Pinion Steering Gear (3)

4. Install the 1 washer (2) to the electric belt drive rack and pinion steering gear.

5. Install Steering Gear Nut(1)@Electric Belt Drive Rack and Pinion Steering Gear

6. Install Steering Gear Bolt(4)@Electric Belt Drive Rack and Pinion Steering Gear(3) - Electric Belt Drive Rack and Pinion Steering Gear Replacement

Fig. 69: Stabilizer Shaft And Bolts

Courtesy of GENERAL MOTORS COMPANY

7. Install Stabilizer Shaft (2)

8. Install New Stabilizer Shaft Bracket Bolt (1) and tighten the NEW bolt.Stabilizer Shaft Replacement

Fig. 70: Steering Column Dash Outer Seal Courtesy of GENERAL MOTORS COMPANY

9. Make sure the notch in the steering column dash outer seal (1) is still correctly aligned to the nose on the electric belt drive rack and pinion steering gear.

NOTE: Pivot the electric belt drive rack and pinion steering forward as the drivetrain and front suspension cradle is being raised up to the vehicle. Insert the front horns of the drivetrain and front suspension cradle into the drivetrain and front suspension cradle extension as the drivetrain and front suspension cradle gets closer to the body. Once the drivetrain and front suspension cradle is inserted into the drivetrain and front suspension cradle extension, pivot the steering gear rearward so steering shaft goes up into the floor as the cradle is raised up to the vehicle.

10. Raise the drivetrain and front suspension cradle to the vehicle.

Fig. 71: Drivetrain And Front Suspension Crossmember Extension Fasteners Courtesy of GENERAL MOTORS COMPANY

11. Insert NEW Drivetrain and Front Suspension Crossmember Extension Rear Bolt (2) - Install the NEW bolts snug

12. Install New Drivetrain and Front Suspension Cradle Nut (1)

Fig. 72: Electric Belt Drive Rack And Pinion Steering Gear, Bolts, Nuts And Washers Courtesy of GENERAL MOTORS COMPANY

13. Install the two washers (2) to the electric belt drive rack and pinion steering gear.

14. Install the remaining steering gear bolts (4), washers (2) and nuts (1). Electric Belt Drive Rack and Pinion Steering Gear Replacement

Fig. 73: Power Steering Assist Motor And Electrical Connectors Courtesy of GENERAL MOTORS COMPANY

15. Connect Electrical Connector(1)@Power Steering Assist Motor(2)

16. Connect Electrical Connector(3)@Power Steering Assist Motor(2)

Fig. 74: Drivetrain And Front Suspension Cradle And Alignment Pins Courtesy of GENERAL MOTORS COMPANY

17. Install the 2 CH-51034-A cradle alignment pins (1, 3) to arrange the drivetrain and front suspension cradle during tightening.

18. Make sure that the drivetrain and front suspension cradle (2) fits closely to the vehicle.

19. Make sure that the 2 CH-51034-A cradle alignment pins fit closely to the drivetrain and front suspension cradle (2).

Fig. 75: Steering Column Dash Outer Seal, Electric Belt Drive Rack And Pinion Steering Gear Courtesy of GENERAL MOTORS COMPANY

20. Make sure the steering column dash outer seal (3) fits correctly on the electric belt drive rack and pinion steering gear (2). See arrows.

21. Make sure the steering column dash outer seal (3) fits correctly on the dash panel front lower cross bar

(1). See arrows.

22. Wiring Harness@Drivetrain and Front Suspension Cradle - Connect as necessary

23. Wiring Harness@Electric Belt Drive Rack and Pinion Steering Gear - Connect as necessary

Fig. 76: Transmission Mount Strut Bolt And Transmission Mount Strut Courtesy of GENERAL MOTORS COMPANY

24. Install New Transmission Mount Strut Bolt(1)@Transmission Mount Strut(2) - Do NOT tighten.

Transmission Mount Strut Replacement

Fig. 77: Drivetrain And Front Suspension Cradle Bolts Courtesy of GENERAL MOTORS COMPANY

WARNING: Torque-to-Yield Fastener Warning

25. Install New Drivetrain and Front Suspension Cradle Bolt (2)

Tighten:

1. First Pass:70 N.m (52 lb ft)

2. Final Pass:45 - 60 degrees, use the EN-45059 meter

Fig. 78: Drivetrain And Front Suspension Crossmember Extension Fasteners Courtesy of GENERAL MOTORS COMPANY

WARNING: Torque-to-Yield Fastener Warning

26. Install New Drivetrain and Front Suspension Crossmember Extension Rear Bolt (2) Drivetrain and Front Suspension Crossmember Extension Replacement

27. Install New Drivetrain and Front Suspension Crossmember Extension Bolt (3) Drivetrain and Front Suspension Crossmember Extension Replacement

28. Install New Drivetrain and Front Suspension Cradle Nut (1)

Tighten

1. First Pass:100 N.m (74 lb ft)

2. Final Pass: 45 - 60 Degrees, use the EN-45059 Angle Meter

Fig. 79: Transmission Mount Strut Bolt And Transmission Mount Strut Courtesy of GENERAL MOTORS COMPANY

WARNING: Torque-to-Yield Fastener Warning

29. Install New Transmission Mount Strut Bolt(1)@Transmission Mount Strut (2)Transmission Mount Strut Replacement

Fig. 80: Stabilizer Shaft Link, Stabilizer Shaft And Nut Courtesy of GENERAL MOTORS COMPANY

NOTE: Hold against the hex of the threaded stud to tighten the nuts. Use a suitable tool.

NOTE: Support the front suspension with a hydraulic jack to connect the stabilizer shaft links.

30. Connect Stabilizer Shaft Link(1)@Stabilizer Shaft(3)

31. Install Stabilizer Shaft Link Nut(2)@Stabilizer Shaft Link(1) and tighten the nut Stabilizer Shaft Replacement

32. Connect the outer tie rod to the steering knuckle.Steering Linkage Outer Tie Rod Replacement

Fig. 81: Steering Knuckle, Lower Ball Joint And Nut Courtesy of GENERAL MOTORS COMPANY

NOTE: Support the lower control arm under the ball joint with a hydraulic jack to tighten the nut.

33. Install the lower ball joint stud (3) to the steering knuckle (2).

WARNING: Torque-to-Yield Fastener Warning

34. Install Lower Ball Joint Nut (1)Lower Control Arm Replacement

Fig. 82: Radiator Air Side Baffle Bolt And Radiator Air Lower Baffle Bracket Courtesy of GENERAL MOTORS COMPANY

35. Radiator Air Side Baffle Bolt (1) @Radiator Air Lower Baffle Bracket (2) and tighten Radiator Air Lower Baffle and Deflector Replacement

Fig. 83: Heater Water Bypass Valve Bracket Bolt And Heater Water Bypass Valve Bracket Courtesy of GENERAL MOTORS COMPANY

36. Install Heater Water Bypass Valve Bracket Bolt (1) @Heater Water Bypass Valve Bracket (2) and tighten

Heater Water Shutoff Valve Replacement

37. Install Exhaust Muffler Exhaust Muffler Replacement

Fig. 84: Drivetrain And Front Suspension Cradle, Brace And Bolt Courtesy of GENERAL MOTORS COMPANY

38. Install the drivetrain and front suspension brace (2) to the drivetrain and front suspension cradle (1).

39. Install Drivetrain and Front Suspension Cradle Bolt (3) and tighten 58 N.m (43 lb ft)

40. Install Front Underbody Air Deflector Front Underbody Air Deflector Replacement

41. Install Front Wheelhouse Liner Front Wheelhouse Liner Replacement (Left Side)Front Wheelhouse

Liner Replacement (Right Side)

42. Install the front tire and wheel assemblies. Tire and Wheel Removal and Installation

43. Connect the steering intermediate shaft to the steering gear. Intermediate Steering Shaft Replacement

44. Enable the high voltage system. High Voltage Enabling

45. Check the steering wheel angle sensor centering. Steering Wheel Angle Sensor Centering

FRONT WHEELHOUSE LINER REPLACEMENT (LEFT SIDE)

Fig. 85: Front Wheelhouse Liner (Left Side) Courtesy of GENERAL MOTORS COMPANY

FRONT WHEELHOUSE LINER REPLACEMENT (RIGHT SIDE)

Fig. 86: Front Wheelhouse Liner (Right Side) Courtesy of GENERAL MOTORS COMPANY

REAR WHEELHOUSE LINER REPLACEMENT

Fig. 87: Rear Wheelhouse Liner

Courtesy of GENERAL MOTORS COMPANY

FRONT TIRE FRONT AIR DEFLECTOR REPLACEMENT

Fig. 88: Front Tire Front Air Deflector Courtesy of GENERAL MOTORS COMPANY

REAR TIRE FRONT AIR DEFLECTOR REPLACEMENT

Fig. 89: Rear Tire Front Air Deflector Courtesy of GENERAL MOTORS COMPANY

FLOOR PANEL NUMBER 4 CROSS BAR REPLACEMENT

Removal Procedure

1. Raise and support the vehicle. Lifting and Jacking the Vehicle

Fig. 90: Fuel Tank And Suitable Jack

Courtesy of GENERAL MOTORS COMPANY

2. Remove Fuel Tank (1)Fuel Tank Replacement

3. Support the drive motor battery with a suitable jack.

Fig. 91: Floor Panel Number 4 Crossbar, Drive Motor Battery Tray Bolts And High Voltage Battery Hold Down Retainer Bolts

Courtesy of GENERAL MOTORS COMPANY

4. Remove Drive Motor Battery Tray Bolt (1)

5. Remove High Voltage Battery Hold Down Retainer Bolt (2)

6. Remove High Voltage Battery Hold Down Retainer Bolt (3)

7. Remove Floor Panel Number 4 Crossbar (4)

Installation Procedure

Fig. 92: Floor Panel Number 4 Crossbar, Drive Motor Battery Tray Bolts And High Voltage Battery Hold Down Retainer Bolts

Courtesy of GENERAL MOTORS COMPANY

1. Install Floor Panel Number 4 Crossbar (4)

CAUTION: Refer to Fastener Caution .

2. Install Drive Motor Battery Tray Bolt (1) and tighten 22 N.m (16 lb ft)

3. Install High Voltage Battery Hold Down Retainer Bolt (2) and tighten 58 N.m (43 lb ft)

4. Install High Voltage Battery Hold Down Retainer Bolt (3) and tighten 22 N.m (16 lb ft)

5. Remove the drive motor battery support jack.

Fig. 93: Fuel Tank And Suitable Jack

Courtesy of GENERAL MOTORS COMPANY

6. Install Fuel Tank (1)Fuel Tank Replacement

7. Lower the vehicle.

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS

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