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REMOVE OR DISCONNECT 1. Retainer and electrical connector from fluid level sensor. 2. Drain brake fluid front mister cylinder reservoir. 3. Reservoir hose from master cylinder. Plug hose to prevent fluid loss and contamination. 4. Brake pipes from master cylinder. Plug open pipes to prevent fluid loss and contamination. 5. Two attaching nuts. 6. Master cylinder. 7. Reservoir, if it is to he used on replacement master cylinder. INSTALL OR CONNECT Reservoir onto master cylinder, as needed. Master cylinder on to power booster. Attaching nuts. Tighten to 27 Nm (20 lb. ft.). Brake pipes. Tighten brake pipe fittings to 15 Nm (11 lb. ft.). Reservoir hose onto master cylinder. Fill master cylinder reservoir to full level mark using only Delco Supreme 11 Brake Fluid, or equivalent DOT 3 brake fluid. 7. Electrical connector to fluid level sensor, secure with retainer. 8. Bleed hydraulic system. 9. Recheck fluid level in reservoir. 1. 2. 3. 4. 5. 6.

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Steering Vibration/Shudder/Moan During Parking Maneuvers on Dry Pavement (Install Power Steering Pressure (Inlet) and/or Return (Outlet) Hose Assembly) 1995-99 Buick Riviera 1997-2001 Buick Park Avenue, Ultra 2000-2001 Buick LeSabre 2000-2001 Pontiac Bonneville steering vibration, shudder or moan noise when steering during parking maneuvers on dry pavement. Correction Install a new power steering pressure (inlet) hose assembly on the following vehicles: • 1995-98 Buick Riviera • 1997-98 Buick Park Avenue and Ultra Install a new power steering pressure (inlet) and return (outlet) hose assembly on the following vehicles: • 1999 Buick Riviera • 1999-2001 Buick Park Avenue and Ultra • 2000-2001 Buick LeSabre • 2000-2001 Pontiac Bonneville 1. Verify that the power steering pump reservoir is full. • If fluid level is low, fill and check for leaks. • If power steering system has air in the system, perform the “Bleeding Air from Power Steering System” procedure as described in the Power Steering System sub-section of the Service Manual. Important: When performing the “Bleeding Air from Power Steering System” procedure, it is important that the front of the vehicle is supported by the lower control arms. If the vehicle is not supported by the lower control arms, the procedure may cause the strut bushing to dislocate and cause new concern. Verify that the accessory drive belt is in good condition and that the pulleys are not bent or damaged. Verify proper belt tension and operation of the belt tensioner. Check for power steering hose ground out conditions. Check for good engine idle and correct engine RPM. Check to see that the rear transaxle mount does not have a plastic assembly aid installed which is used 2. 3. 4. 5. 6.

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Removal CAUTION: Remove the entire clutch hydraulic system from the vehicle as an assembly when installing a new clutch master cylinder assembly (7C522). 1. Disconnect the clutch hydraulic tube from the dash clip. 2. Raise and support the vehicle. For additional information, refer to Section 100-02. 3. Unlock and remove the slave cylinder (7A564) from the transmission. Compress and twist the slave cylinder to unlock it from the transmission. 4. Disconnect the clutch hydraulic tube from the floor pan clip. Position the slave cylinder and hydraulic tube forward below the left engine bank. This will make it easier to unlock the clutch master cylinder from the clutch pedal and support bracket (7B633) by reducing tension on the hydraulic tube. 5. Lower the vehicle. 6. WARNING: The clutch pedal is under spring tension. Unlock the push rod bushing retaining clips and separate the clutch master cylinder push rod from the clutch pedal. 7. Remove and discard the push rod bushing (7526). 8. Remove the switch cover, and remove the clutch pedal position switch (7C534) from the clutch master cylinder push rod. 9. Separate the power distribution box from the bracket to gain access to the clutch master cylinder. 10. Unlock and remove the clutch master cylinder from the clutch pedal and support bracket. Compress and twist the clutch master cylinder clockwise 45 degrees to unlock it from the clutch pedal and support bracket. 11. Remove the clutch hydraulic reservoir from the wiring tray and separate the clutch hydraulic tube from the brake master cylinder assembly. Position the clutch hydraulic reservoir aside. 12. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. Remove the clutch hydraulic system from the vehicle. 13. Clean the clutch hydraulic system components to prevent contaminants from entering the hydraulic system. 14. CAUTION: Place a suitable container under the clutch master cylinder. Disconnect the hydraulic tube from the clutch master cylinder. 1. Using a 3/32-inch punch and a hammer, drive out the roll pin, and discard it. 2. Disconnect the hydraulic tube from the clutch master cylinder.

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1. 2. 3. 4. 5. Drain the coolant and disconnect the upper radiator hose. Remove the breather hose (between the air cleaner and the rocker cover). Remove the air-intake hose. Remove the vacuum hose, fuel hose and coolant hose. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion. Remove the ignition coil. Remove the surge tank. Remove the intake manifold. Remove the heat protector and exhaust manifold assembly Remove the coolant pump pulley and the crankshaft pulley. Remove the timing belt cover. 6. 7. 8. 9. 10. 11. Zoom Sized for Print 12. Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it. 13. Remove the timing belt. 14. Remove the rocker cover. 15. Remove the cylinder head assembly. The cylinder head bolts should be removed using Special Tool, Cylinder Head Bolt Wrench (09221-21000), in the sequence as shown in the illustration. 16. Remove the gasket pieces from the cylinder block top surface and cylinder head bottom surface. NOTE: 1. Make sure that the gasket pieces do not fall in to the engine. INSPECTION 1. Check the cylinder head for cracks, damage and coolant leakage. 2. Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed air to make certain that the passages are not clogged. 3. Check the cylinder head surface for flatness using a straight edge in the direction of A, B, …as shown. If flatness exceeds service limit in any direction, replace the cylinder head, or lightly machine the cylinder head surface. Cylinder head flatness Standard value: Less than 0.03 mm (0.0012 inch) Limit: 0.08 mm (0.0031 inch) REASSEMBLY 1. Clean all gasket surfaces of the cylinder block and the cylinder head. 2. Install a new cylinder head gasket onto the cylinder head assembly. Do not apply sealant to the gasket and do not reuse the old cylinder head gasket.

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Engine Electrical > Firing Orders Firing Orders To avoid confusion, always replace spark plugs and wires one at a time. Replacing spark plugs and wires one at a time will help prevent incorrect wire routing or cross-firing resulting from an incorrect firing order. If more than one wire is to be disconnected at a single time, be sure to tag all of the cables to assure proper installation. Also, be disconnecting the cables, compare the firing order and routing to these diagrams and note any differences for installation purposes. This will help assure the wires are properly installed.