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Condition Some customers of 1999-2002 Chevrolet Malibu, Oldsmobile Alero, Pontiac Grand Am, and 1999 Oldsmobile Cutlass may have turn signal/hazard flashers that become inoperative.Service Procedure The following procedure provides instructions for replacing the hazard warning switch located in the instrument panel (I/P). For additional information, refer to the Lighting subsection in the Body and Accessories section of the appropriate Service Manual or SI. Malibu 1. Remove the cover from the left side instrument panel (I/P) wiring harness junction block access panel. 2. Remove the AIR BAG fuse from the panel. 3. Remove the three screws attaching the lower steering column cover to the steering column. 4. Remove the upper steering column cover. 5. Remove the two screws that attach the IP cluster bezel to the IP. 6. Using a small flat-blade screwdriver, gently pry out and remove the IP cluster trim plate from the IP. 7. Disconnect the electrical connectors from the other switches in the trim plate. 8. Disconnect the electrical connector from the hazard warning switch. 9. Using a small flat-blade screwdriver, carefully push in on the tabs to release the hazard warning switch from the IP cluster trim plate. 10. Remove the hazard warning switch by pushing in an outward motion on the switch while holding onto the IP cluster trim plate. 11. Install the new hazard warning switch by pushing in an inward motion on the switch while holding onto the IP cluster trim plate. Push inward on the switch until it is fully seated into the IP cluster trim plate. 12. Connect the electrical connector to the hazard warning switch. 13. Connect the electrical connectors to the other switches in the trim plate. 14. Position and align the IP cluster trim plate to the IP and carefully press into place.

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Model(s): 1994-95 Buick Regal 1994-97 Buick Skylark 1994-98 Buick Century 1994-95 Chevrolet Beretta Corsica, Lumina, Monte Carlo 1996-98 Chevrolet Venture 1997-98 Chevrolet Malibu 1993-97 Oldsmobile Cutlass Supreme 1994-96 Oldsmobile Cutlass Ciera 1994-97 Oldsmobile Achieva 1996-98 Oldsmobile Silhouette 1997-98 Oldsmobile Cutlass 1994-98 Pontiac Grand Am, Grand Prix 1996-98 Pontiac Trans Sport with 3100, 3400 V6 Engine (VINs M, E – RPOs ticking type noise that begins shortly after cold engine start-up and gradually diminishes as the engine warms up. In most cases, the noise is gone after five (5) minutes. In severe cases, the noise may not disappear when lhe engine is hot. Under normal design tolerances when the piston pin bore is produced at the maximum tolerance and the piston pin is produced at the minimum tolerance (min-max tolerance) trace noise levels can occur. This level of noise does not affect the reliability or durability of the product. If piston-to-pin noise is detected and the customer desires the condition to be corrected, replace all six pistons with pin assemblies. The new piston sets have a minimal piston-to-pin clearance. Remember, piston-to-pin noise occurs in both park and drive at engine idle rpm and it varies in intensity depending on the number of pistons involved. A ticking sound means one piston is affected whereas a rattle or diesel type sound indicates more than one piston affected. The following should also be checked: 1. On W-Cars, make sure the right side engine splash shield is not contacting the engine crankshaft balancer. This condition usually happens cold and is caused by the shield curling when cold. 2. Reference Service Bulletin 57-71-06 for transmission rattle noise often confused for engine rattle noise. 3. Reference Service Bulletin 47-61-36 for Accessory Drive Belt Tensioner noise. 4. Check cylinder bore diameter and piston diameter as outlined in the Service Manual.

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1. Disconnect the brake booster vacuum check valve (1) from the brake booster. 2. If the vacuum check valve (1) needs to be separated from the vacuum hose (3), release and reposition the clamp (2) on the vacuum hose (3) and remove the check valve (1) from the hose (3). 3. If replacing the vacuum check valve (1), remove the grommet (4) from the brake booster and discard the grommet. 4. If removing the vacuum hose (2), take note of the vacuum hose routing then disconnect from the engine intake manifold connection (3) by releasing tension on the vacuum hose clamp (1) and sliding the vacuum hose (2) off the intake manifold connection (3). Installation Procedure Important: A small amount of denatured alcohol can be used as an assembly aid when installing the vacuum check valve and/or grommet. Do NOT use soap. 1. If the vacuum hose (2) was removed, install the vacuum hose into position on the vehicle as noted prior to removal, then connect the vacuum hose (2) to the engine intake manifold connection (3) and secure with the vacuum hose clamp (1). 2. If the vacuum check valve (1) is being replaced, install a NEW grommet (4) to the brake booster. 3. If the vacuum check valve (1) was separated from the vacuum hose (3), install the check valve (1) to the vacuum hose (3). Install and secure the clamp (2) into position on the hose (3). 4. Connect the brake booster vacuum check valve (1) to the brake booster.

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REMOVAL PROCEDURE 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the front door trim panel insert from the door. Remove the front door handle bezel. Remove the power accessory switch panel. Use a flat bladed tool in order to remove the inside door pull handle plug. Remove the door trim panel screws from under the inside pull handle. Remove the window regulator handle, if equipped. Using J 38778 and starting at the door bottom, disengage the door trim panel retainers. Lift up on the door trim panel to disengage it from the inner belt molding. Remove the door trim panel from the door. INSTALLATION PROCEDURE 1. Position the door trim panel on the inner belt molding and press down. 2. Install the front door trim panel to the door, pressing into place until the retainers are fully seated. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the door trim panel screws to the door trim panel. Tighten Tighten the door trim panel screws to 10 N.m (89 lb in). 2001 Chevrolet Malibu V6-3.1L VIN J 4. 5. 6. 7. 8. Install the window regulator handle, if equipped. Install the inside door pull handle plug to the door trim panel, pressing until fully seated. Install the inside door handle bezel to the door trim panel. Install the power accessory switch panel to the door trim panel. Install the front door trim panel insert to the door.

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TRIM PANEL REPLACEMENT – SIDE FRONT DOOR REMOVAL PROCEDURE 1. Using a non-marring tool, remove the door trim fastener cover. 2. Remove the door trim fasteners. 3. Remove the fasteners at the rear of the door trim by first pushing in the center of the fastener. 4. Using a non-marring tool to release the fasteners, remove the door trim. 2005 Chevrolet Malibu V6-3.5L VIN 8 5. If you are installing a new door trim, remove the trunk release switch from the door trim. INSTALLATION PROCEDURE 1. Install the trunk release switch, if necessary.