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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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Caution: Refer to Battery Disconnect Caution in Service Precautions. Notice: Refer to Use GM Goodwrench DEX-COOL Coolant in Service Precautions. 1. 2. 3. 4. 5. Disconnect the negative battery cable. Drain the cooling system. Recover the coolant. Refer to Service and Repair. Remove the drive belt. Remove the water pump pulley bolts. Remove the water pump pulley. 6. Remove the coolant pump attaching bolts. 7. Remove the coolant pump. 8. Clean the coolant pump and the sealing surfaces. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the water pump and new gasket. Tighten the bolts to 10 Nm (89 inch lbs.) . 2. Install the water pump pulley and the bolts. 3. Install the drive belt. 4. Tighten the water pump pulley bolts. Tighten the bolts to 25 Nm (18 ft. lbs.) . 5. Connect the negative battery cable. Tighten the bolts to 16 Nm (12 ft. lbs.) . 6. Refill the cooling system. Refer to Service and Repair. 7. Inspect the cooling system for leaks.

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1. 2. 3. 4. Disconnect the electrical connector at EGR valve. Remove the 2 EGR Valve retaining nuts. Remove the Linear EGR valve assembly. Remove the gasket. INSTALLATION PROCEDURE 1. Clean the intake surface and install the gasket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the linear EGR valve assembly and two bolts. Tighten Tighten the nuts to 30 N.m (22 lb. ft.). 3. Connect the electrical connector.

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1. 2. 3. 4. 5. Disconnect all the electrical connectors at the ignition control module. Note position of spark plug wires for installation and disconnect the spark plug wires from ignition coils. Remove the screws securing coil assemblies to ignition control module. Disconnect the coils from ignition control module. Remove the ignition control module from the bracket. INSTALLATION PROCEDURE 1. Install the ignition control module on the bracket. 2. Install the coils to ignition control module. NOTE: Refer to Fastener Notice in Service Precautions. 3. Reinstall the screws. Tighten Tighten the screws to 4.5 N.m (40 lb in). 4. Connect the spark plug wires as noted during removal. 5. Connect the electrical connectors to the ignition control module.

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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