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Home >> Chevrolet >> 1996 >> Lumina V6-204 3.4L DOHC VIN X SFI >> Repair and Diagnosis >> Powertrain Management >> Computers and Control Systems >> Technical Service Bulletins >> Recalls >> Recall - Air Injection Pump Failure >> Service Procedure

Service Procedure

IMPORTANT:
The service procedure contained in this recall is different from the service procedure found in the appropriate service manual(s). In the near future the service manual(s) will be updated with this new service procedure. Please be advised that the labor time allowance listed in the labor time guide is not affected by this new service procedure.

1996 3.4L DOHC AIR Pump Procedure

1. Open AIR pump kit p/n 88880033, remove and discard the following:

[ ] Label p/n 12568750

[ ] Nut p/n 10242827

[ ] Vacuum harness attached to solenoid.

[ ] Hose and two clamps attaching shut-off valve to AIR pump outlet

[ ] Isolators and compression limiters from AIR pump





2. Remove the fuel rail sight shield and disconnect the HVAC vacuum connector to the intake manifold. Route the new vacuum harness on the top of the engine forward of the fuel rail, and connect the 1/4" fitting to the intake manifold port and connect the HVAC hose to the open fitting on the new harness. Add wire ties as shown to secure new vacuum line.








3. Feed the vacuum harness past the Power steering reservoir, under the wiring harness, over the AIR hose and down then through the gap between the inner tender and the frame just forward of where the AIR hose goes through.





4. Reinstall the fuel rail sight shield.

5. Raise the vehicle, remove right front wheel and tire assembly.

6. Remove fasteners attaching the front part of fender liner so that liner can be moved back to allow access to AIR pump.





7. Disconnect pump outlet hose from "TEE" hose coupling.

8. Disconnect electrical wire harness from the bleed solenoid and from the AIR pump.

9. Remove and save the three (3) pump bracket to frame rail fasteners. Remove pump and bracket assembly from vehicle.





10. Remove and discard:

[ ] Bleed solenoid and fastener

[ ] Any hoses connected to inlet side of filter.

11. Remove inlet hose and filter from original AIR pump and attach with same clamp to inlet of new AIR pump.

12. Cut 34 inch off pump end of outlet hose and attach to outlet side of new pump with existing clamp

13. Remove and discard the short nylon and rubber tube outlet assembly.





14. Assemble the new AIR pump and bracket using the new isolators, compression limiters and fasteners provided.

15. Bend anti rotation tab on new solenoid out and flat with remainder of bracket.





16. Attach the AIR pump and bracket assembly, and the vacuum solenoid, to the frame rail (using the original fasteners. Note: solenoid is attached at the rear fastener location, over the bracket, and must be positioned vertically with the vacuum ports down and the splash cap up.

17. Push the check valve and hose fully onto the TEE" hose coupling and clamp then push the outlet hose from the AIR pump fully onto the inlet of the shut-off valve and clamp.





18. Connect the short vacuum hose to the higher port on the solenoid, and to the vacuum port on the shut-off valve.

19. Connect the vacuum supply harness to the bottom port on the vacuum solenoid.

20. Connect the electrical wiring to the AIR pump, and close off the (unused) bleed solenoid connector using plug P/N 12064959. Tape bleed solenoid connector to harness with electrical tape.





21. Connect the AIR pump jumper wiring harness to the vacuum solenoid

22. Attach the "S" shaped end of the new inlet hose to the filter (using the same clamp removed earlier) and route the hose into the engine compartment through the gap between the inner fender and the frame forward of the AIR hose to the front bank check valve and rearward of the wiring harness bundle.





23. Position this inlet hose up alongside and forward of the front bank check valve hose. (Caution: if the new inlet is not forward of the right bank check valve hose it may interfere with the AC compressor pulley)

24. Lower vehicle

25. Install splash cap on inlet hose





26. Using the tie strap (2), support the vacuum harness and AIR pump inlet (3) (near the splash cap) to the front bank check valve hose.

27. Verify system function with Tech 2, repair as necessary.

28. Clear codes

29. Raise vehicle.

30. Reinstall fenderwell splash shield and right front tire.

31. Lower vehicle

32. Attach emissions label P/N 12580971 over the existing emissions label.

33. Install the GM Recall Identification Label.

34. CALIFORNIA VEHICLES ONLY: Complete a "Proof Of Correction" certificate upon recall completion.
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