Filed Under (Pontiac) by admin on 16-09-2010
Important: Use the following steps in order to reset the timing chain tensioner assembly to the zero position. 1. Reset the timing chain tensioner assembly. A. B. C. D. Insert the tensioner plunger assembly into the tensioner housing. With the tensioner plunger fully extended, turn the complete assembly upside down on a bench or other flat surface. With the plunger face against the workbench, press firmly on the boffom of the tensioner housing. Compress the plunger until the plunger is seated flush in the tensioner. 2. Check the plunger to make sure that the plunger is out of the cylinder at the correct dimension. The correct dimension for the plunger to extend out of the cylinder is 1.7 mm ( 0.070 in ) maximum 1999 Pontiac Grand AM L4-144 2.4L DOHC VIN T SFI 3. Loosely install the tensioner assembly and bolts to the timing chain housing. 4. Install the timing chain tensioner shoe on the stud. 5. Apply hand pressure to the timing chain tensioner shoe until the locking tab seats in the groove in the stud. Notice: Do not over tighten the bolts retaining the component or failure to the component may occur. 6. Tighten the timing chain tensioner bolts. Tighten
Filed Under (Pontiac) by admin on 11-09-2010
SPECIAL TOOL REQUIRED (or equivalent) ^ J-33039-A, Cam drive belt tension adjustment wrench. NOTE: O.E. manuals do NOT provide images of the timing marks, however, the alignment marks are located on the camshaft and crankshaft gears and the rear timing belt cover. REMOVE OR DISCONNECT 1. Battery ground cable, then partially drain cooling system. 1991 Pontiac J2000/Sunbird L4-121 2.0L 2. 3. 5. 6. 7. 8. 9. Coolant recovery reservoir. Serpentine, A/C and/or P/S drive belts (if equipped). Crankshaft pulley. Timing belt cover attaching bolts and the cover. Align marks on timing gears with the marks on the rear timing cover. Loosen water pump bolts, then using J-33039-A on the water pump eccentric, release the belt tension. Timing belt. INSTALL OR CONNECT 1. Turn crankshaft and camshaft gears clockwise to align timing marks on timing belt rear cover. 2. Timing belt, making sure that the portion between the crankshaft and camshaft gears is in tension. 3. Using J-33039-A rotate water pump eccentric clockwise until tensioner contacts high torque stop, then tighten water pump bolts slightly. 4. Rotate the engine by the crankshaft gear bolt 720° clockwise to seat timing belt on sprockets. 5. With engine at room temperature, rotate water pump eccentric with J-33039-A counterclockwise until hole in tensioner arm is inline with hole in base. 6. Tighten water pump attaching bolts to 25 Nm (18 ft lbs) and ensure tensioner holes remain aligned. 7. Timing belt cover and tighten bolts and nuts to 9 Nm (80 in lbs). 8. Crankshaft pulley, apply Loctite(R) 242 to bolt threads and tighten to 21 Nm (15 ft lbs). 10. Serpentine, A/C and/or P/S drive belts (if equipped). 11. Coolant recovery reservoir and fill cooling system. 12. Battery ground cable.
Filed Under (Pontiac) by admin on 10-09-2010
1. If equipped with an automatic transmission, remove the exhaust manifold. 2. Drain the cooling system. 3. Remove the thermostat housing to water pump feed pipe bolts. 4. Remove the thermostat housing to water pump feed pipe. 5. Remove the thermostat. 2004 Pontiac Sunfire L4-2.2L VIN F Installation Procedure 1. Install the thermostat. 2. Install the thermostat housing to water pump feed pipe. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the thermostat housing to water pump feed pipe bolt. ^ Tighten the thermostat housing to water pump feed pipe bolt to 10 Nm (18 inch lbs.). 4. If equipped with an automatic transmission, install the exhaust manifold. 5. Fill the cooling system.
Filed Under (Pontiac) by admin on 09-09-2010
The front inside door handle bezel has electrical connectors, the rear does not. 1. Insert a flat bladed tool behind the forward upper edge of the door handle bezel. 2. Gently pry the upper portion of the bezel away from the door trim panel. 3. Pull the bezel forward over the inside door handle. 4. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. 2. 3. 4. Connect the electrical connectors, if any, to the inside door handle bezel. Guide the inside door handle through the opening in the door handle bezel. Snap the door handle bezel into place. Work the rubber around and behind both the manual lock knob and the inside door handle.
Filed Under (Pontiac) by admin on 03-09-2010
Legend (1) Auto Level Control (ALC) Harness (2) Auto Level Control (ALC) Sensor Legend (1) Auto Level Control (ALC) Inflator Solenoid Valve (2) Inflator Air Switch (3) Body Harness (4) Rear Electric Accessory Plug Housing (5) Auto Level Control (ALC) Inflator Relay (6) Auto Level Control Harness Behind Rear Left Wheelhouse Legend (1) Pass Through P403 (2) In-line connector C407 (3) Auto Level Control Harness (4) Auto Level Control (ALC) Sensor Connector (5) Auto Level Control (ALC) Air Compressor (6) Auto Level Control (ALC) Compressor Relay (7) Auto Level Control (ALC) Connector Below Vehicle, Rear Of LR Wheelhouse