Pontiac Solstice 2010 User Manual

2009 Pontiac Solstice

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SKY, Solstice (VIN M) Service Manual

Document ID: 1581636

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Brakes

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Antilock Brake System

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Specifications

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Fastener Tightening Specifications

Application

Brake Pipe Fittings 20 N·m 15 lb ft Brake Pressure Modulator Assembly Bracket Bolts 10 N·m 89 lb in Brake Pressure Modulator Assembly Bracket Bolt 11 N·m 97 lb in Electronic Brake Control Module (EBCM) Bolts 2.3 N·m 20 lb in Master Cylinder Nuts 20 N·m 15 lb ft Yaw Sensor Nuts 10 N·m 89 lb in

Specification

Metric English

2009 Pontiac Solstice

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SKY, Solstice (VIN M) Service Manual

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Brakes

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Antilock Brake System

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Repair Instructions

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Antilock Brake System Automated Bleed Procedure

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface

section.

Note: Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed of the base brake system. Refer to Hydraulic Brake System Bleeding. The automated bleed procedure is recommended when one of the following conditions exist:

• Base brake system bleeding does not achieve the desired pedal height or feel

• Extreme loss of brake fluid has occurred

• Air ingestion is suspected in the secondary circuits of the brake modulator assembly

The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out toward the brake corners.

Performing the Automated Bleed Procedure

Caution: The Auto Bleed Procedure may be terminated at any time during the process by

pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces.

1. Raise and support the vehicle. Refer to Lifting and

2. Remove all four tire and wheel assemblies. Refer to Tire and

3. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic

Brakes. Repair or replace components as needed.

4. Lower the vehicle.

5. Inspect the battery state of charge. Refer to Battery

6. Install a scan tool.

7. Turn the ignition ON, with the engine OFF.

8. With the scan tool, establish communications with the ABS system. Select Special Functions. Select Automated Bleed from the Special Functions menu.

9. Raise and support the vehicle. Refer to Lifting and

10. Following the directions given on the scan tool, pressure bleed the base brake system. Refer to Hydraulic

11. Follow the scan tool directions until the desired brake pedal height is achieved.

12. If the bleed procedure is aborted, a malfunction exists. Perform the following steps before resuming the bleed procedure:

• If a DTC is detected, refer to Diagnostic the appropriate DTC.

• If the brake pedal feels spongy, perform the conventional brake bleed procedure again. Refer to Hydraulic Brake System Bleeding.

13. When the desired pedal height is achieved, press the brake pedal to inspect for firmness.

Brake System Bleeding.

Trouble Code (DTC) List - Vehicle , and diagnose

Jacking the Vehicle.

Wheel Removal and Installation.

Inspection/Test.

Jacking the Vehicle.

14. Lower the vehicle.

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15. Remove the scan tool.

16. Install the tire and wheel assemblies. Refer to Tire and

17. Inspect the brake fluid level. Refer to Master Cylinder Reservoir Filling.

18. Road test the vehicle while inspecting that the pedal remains high and firm.

Wheel Removal and Installation.

2009 Pontiac Solstice

performed. Some of these procedures are as

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Brakes

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Antilock Brake System

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Repair Instructions

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Steering Angle Sensor Centering

The steering angle sensor does not require centering often. Centering of the steering angle sensor might be required after certain service procedures are follows:

• Steering gear replacement

• Steering column replacement

• Steering angle sensor replacement

• Intermediate shaft replacement

• Antilock brake system (ABS) controller replacement

• Collision or other physical damage

The steering angle sensor centering procedure can be preformed with a scan tool in the automated center procedure by the following:

1. Using the steering wheel, align the front wheels forward.

2. Set the transmission in the park position.

3. Install the scan tool to the data link connector (DLC).

4. Turn the ignition switch ON, with the engine OFF.

5. Select Chassis/EBCM control system vehicle stability enhancement system (VSES), special function test, and Steering Pos. Sensor Calibration.

6. Follow the scan tool directions to complete the automated centering procedure this should include turning the steering wheel left 5 degrees and right 5 degrees and then straight forward.

7. Clear any DTCs that may be set. Perform the Diagnostic System Check to verify no current DTCs. Refer to Diagnostic

8. Centering of the steering angle sensor is complete.

System Check - Vehicle .

2009 Pontiac Solstice

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Brakes

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Antilock Brake System

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Repair Instructions

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Electronic Brake Control Module Replacement

Removal Procedure

Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with

the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM.

1. Turn the ignition switch to the OFF position.

2. Thoroughly clean the electronic brake control module (EBCM) to brake pressure modulator valve (BPMV) area of any accumulated dirt and foreign material.

3. Disconnect the EBCM electrical connector (1) by lifting the locking tabs on the lower edge of the lever.

4. Position the electrical connector toward the front of the vehicle.

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5. Disconnect the power brake booster vacuum sensor electrical connector (1).

6. Disconnect the brake fluid level indicator switch electrical connector (2).

7. Release the engine wiring harness retaining clip from the master cylinder mounting stud and position the harness (3) downward.

8. Remove the 2 upper EBCM bolts (1).

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9. Remove the 2 lower EBCM bolts (1).

10. Carefully separate the EBCM (1) from the BPMV.

Do not pry the components apart.

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11. If installing a new EBCM, remove the 12 EBCM seals (1).

12. Clean the sealing surface of the BPMV with denatured alcohol and a clean shop cloth and allow to dry.

Installation Procedure

1. If installing a new EBCM, install the 12 EBCM seals (1).

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2. While aligning the brake pressure sensor to the BPMV, carefully install the EBCM (1) to the BPMV.

Do not force the components together.

Caution: Refer to Fastener Caution

in the Preface section.

3. Install the 2 lower EBCM bolts (1) and tighten to 2.3 N·m (20 lb in).

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4. Install the 2 upper EBCM bolts (1) and tighten to 2.3 N·m (20 lb in).

5. Position the engine wiring harness upward and connect the power brake booster vacuum sensor electrical connector (1).

6. Connect the brake fluid level indicator switch electrical connector (2).

7. Install the engine wiring harness (3) retaining clip to the master cylinder mounting stud.

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8. Position the EBCM electrical connector (1) to the EBCM.

Lower the lever until the locking tabs are fully engaged.

9. If installing a new EBCM, program the EBCM. Refer to Control Module References.

10. Perform the Diagnostic

11. Observe the brake pedal feel after performing the diagnostic system check. If the pedal now feels spongy, air may have been introduced into the secondary hydraulic circuit of the brake modulator which then may have been introduced into the primary circuit. If the pedal feels spongy, perform the Antilock Brake System Automated Bleed Procedure.

System Check - Vehicle.

2009 Pontiac Solstice

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SKY, Solstice (VIN M) Service Manual

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Brakes

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Antilock Brake System

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Repair Instructions

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Brake Pressure Modulator Valve Replacement

Removal Procedure

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface

section.

Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM.

1. Turn the ignition switch to the OFF position.

2. Clean the electronic brake control module (EBCM) to brake pressure modulator valve (BPMV) area of any accumulated dirt and foreign material.

3. Disconnect the brake fluid level indicator switch electrical connector.

4. Disconnect the vacuum brake booster vacuum sensor electrical connector.

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5. Release the wiring harness retainer from the master cylinder mounting stud and position the wiring harness downward.

6. Remove and discard the 2 master cylinder nuts.

7. If equipped, disconnect the clutch master cylinder hose from the brake master cylinder reservoir.

Cap the brake fluid reservoir outlet and plug the clutch master cylinder hose inlet to prevent brake fluid loss and contamination.

8. Remove the 2 master cylinder brake pipe fittings from the BPMV.

Cap the brake pipe fittings and plug the BPMV inlet ports to prevent brake fluid loss and

contamination.

toward the front of the vehicle.

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9. Remove the brake master cylinder and master cylinder brake pipes as an assembly.

10. Remove the 2 rear brake pipe fittings (1) from the BPMV.

Cap the brake pipe fittings to prevent brake fluid loss and contamination.

11. Remove the 2 front brake pipe fittings (2) from the BPMV.

Cap the brake pipe fittings to prevent brake fluid loss and contamination.

12. Lift the locking tabs on the lower edge of the EBCM electrical connector (3) and disconnect the electrical connector.

13. Position the EBCM electrical connector and the wiring harness

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14. Remove the 2 upper BPMV bracket bolts (1).

15. Loosen, but do not remove the lower BPMV bracket bolt (2).

16. Remove the brake modulator and bracket assembly (3).

17. Remove the BPMV bolt.

18. Carefully separate the BPMV from the bracket. Do not pry against the accumulator covers on the underside of the BPMV.

19. Remove the EBCM bolts (1).

20. Carefully pull the EBCM (2) from the BPMV (3). Do not pry the components apart.

21. If installing a new BPMV, remove and discard the EBCM O-ring seals (4).

22. If reinstalling the BPMV, clean the sealing surface of the BPMV with denatured alcohol and allow to dry.

Installation Procedure

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1. If installing a new BPMV, install new EBCM O-ring seals (4) to the BPMV (3).

Note: Ensure the brake pressure switch is properly aligned to the BPMV when installing the EBCM. Do not force the components together.

2. Carefully install the EBCM (2) to the BPMV.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the EBCM bolts (1) and tighten to 2.3 N·m (20 lb in).

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4. Inspect the BPMV bracket insulators for damage and replace if necessary.

Note: If necessary, a small amount of denatured alcohol can be used as an assembly aid for installing the BPMV mounting pins to the BPMV bracket.

5. Install the BPMV to the bracket.

6. Install the BPMV bolt and tighten to 11 N·m (97 lb in).

7. Install the brake modulator and bracket assembly (3). Align the BPMV bracket to the lower bracket bolt (2).

8. Install the 2 upper brake modulator bracket bolts (1) and tighten to 10 N·m (89 lb in).

9. Install the lower brake modulator bracket bolt and tighten to 10 N·m (89 lb in).

10. Install the 2 rear brake pipe fittings (1) to the BPMV and tighten to 20 N·m (15 lb ft).

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11. Install the 2 front brake pipe fittings (2) to the BPMV and tighten to 20 N·m (15 lb ft).

12. Connect the EBCM electrical connector (3). Ensure the tabs on the cam lever are securely locked in place.

13. Install the brake master cylinder and brake pipes assembly to the vacuum brake booster.

14. Install the 2 master cylinder brake pipe fittings to the BPMV and tighten to 20 N·m (15 lb ft).

15. If equipped, connect the clutch master cylinder hose to the brake master cylinder reservoir.

16. Install 2 new brake master cylinder nuts and tighten to 20 N·m (15 lb ft).

17. Position the wiring harness upward and install the wiring harness retainer to the master cylinder mounting stud on the vacuum brake booster.

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18. Connect the brake booster vacuum sensor electrical connector.

19. Connect the brake fluid level indicator switch electrical connector.

20. If a new EBCM was installed, program the EBCM. Refer to Control

Module References.

Note: A new BPMV comes with both the primary and secondary circuits pre-filled with brake fluid. If the ignition key has not been cycled after installation, only a base brake bleed is necessary.

21. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.

22. Perform the Diagnostic System Check - Vehicle.

23. Observe the brake pedal feel after performing the diagnostic system check. If the pedal now feels spongy, air may have been introduced into the secondary hydraulic circuit of the brake modulator which then may have been introduced into the primary circuit. If the pedal feels spongy, perform the Antilock

Brake System Automated Bleed Procedure.

2009 Pontiac Solstice

Replacement

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SKY, Solstice (VIN M) Service Manual

Document ID: 2157345

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Brakes

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Antilock Brake System

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Repair Instructions

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Brake Pressure Modulator Valve Assembly

Removal Procedure

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface

section.

Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM.

Note: This procedure applies to vehicles equipped with RPO JL4. The electronic brake control module (EBCM) and the brake pressure modulator valve (BPMV) must be replaced as an assembly and cannot be separated.

1. Turn the ignition switch to the OFF position.

2. Clean the brake pressure modulator assembly area of any accumulated dirt and foreign material.

3. Disconnect the brake fluid level indicator switch electrical connector.

4. Disconnect the vacuum brake booster vacuum sensor electrical connector.

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5. Release the wiring harness retainer from the master cylinder mounting stud and position the wiring harness downward.

6. Remove and discard the 2 master cylinder nuts.

7. If equipped, disconnect the clutch master cylinder hose from the brake master cylinder reservoir.

Cap the brake fluid reservoir outlet and plug the clutch master cylinder hose inlet to prevent brake fluid loss and contamination.

8. Remove the 2 master cylinder brake pipe fittings from the brake modulator assembly.

Cap the brake pipe fittings and plug the BPMV inlet ports to prevent brake fluid loss and

contamination.

toward the front of the vehicle.

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9. Remove the brake master cylinder and master cylinder brake pipes as an assembly.

10. Remove the 2 rear brake pipe fittings (1) from the brake modulator assembly.

Cap the brake pipe fittings to prevent brake fluid loss and contamination.

11. Remove the 2 front brake pipe fittings (2) from the brake modulator assembly.

Cap the brake pipe fittings to prevent brake fluid loss and contamination.

12. Lift the locking tabs on the lower edge of the EBCM electrical connector (3) and disconnect the electrical connector.

13. Position the EBCM electrical connector and the wiring harness

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14. Remove the 2 upper brake modulator assembly bracket bolts (1).

15. Loosen, but do not remove the lower BPMV bracket bolt (2).

16. Remove the brake modulator and bracket assembly (3).

17. Remove the brake modulator assembly bolt.

18. Carefully separate the BPMV from the bracket. Do not pry against the accumulator covers on the underside of the brake modulator assembly.

Installation Procedure

1. Inspect the brake modulator assembly bracket insulators for damage and replace if

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necessary.

Note: If necessary, a small amount of denatured alcohol can be used as an assembly aid for installing the brake modulator assembly mounting pins to the brake modulator assembly bracket.

2. Install the brake modulator assembly to the bracket.

Caution: Refer to Fastener Caution

3. Install the brake modulator assembly bolt.

Tighten Tighten the bolt to 11 N·m (97 lb in).

in the Preface section.

4. Install the brake modulator and bracket assembly (3). Align the brake modulator assembly bracket to the lower bracket bolt (2).

5. Install the 2 upper brake modulator bracket bolts (1).

Tighten Tighten the bolts to 10 N·m (89 lb in).

6. Install the lower brake modulator bracket bolt.

Tighten Tighten the bolt to 10 N·m (89 lb in).

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7. Install the 2 rear brake pipe fittings (1) to the brake modulator assembly.

Tighten Tighten the fittings to 20 N·m (15 lb ft).

8. Install the 2 front brake pipe fittings (2) to the brake modulator assembly.

Tighten Tighten the fittings to 20 N·m (15 lb ft).

9. Connect the EBCM electrical connector (3). Ensure the tabs on the cam lever are securely locked in place.

10. Install the brake master cylinder and brake pipes assembly to the vacuum brake booster.

11. Install the 2 master cylinder brake pipe fittings to the brake modulator assembly.

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Tighten Tighten the fittings to 20 N·m (15 lb ft).

12. If equipped, connect the clutch master cylinder hose to the brake master cylinder reservoir.

13. Install 2 new brake master cylinder nuts.

Tighten Tighten the nuts to 20 N·m (15 lb ft).

14. Position the wiring harness upward and install the wiring harness retainer to the master cylinder mounting stud on the vacuum brake booster.

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15. Connect the brake booster vacuum sensor electrical connector.

16. Connect the brake fluid level indicator switch electrical connector.

17. If a new brake modulator assembly was installed, program the brake modulator assembly. Refer to Control

Note: A new brake modulator assembly comes with both the primary and secondary circuits pre-filled with brake fluid. If the ignition key has not been cycled after installation, only a base brake bleed is necessary.

18. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.

19. Perform the Diagnostic System Check - Vehicle.

20. Observe the brake pedal feel after performing the diagnostic system check. If the pedal now feels spongy, air may have been introduced into the secondary hydraulic circuit of the brake modulator which then may have been introduced into the primary circuit. If the pedal feels spongy, perform the Antilock

Module References.

Brake System Automated Bleed Procedure.

2009 Pontiac Solstice

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Brakes

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Antilock Brake System

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Repair Instructions

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Brake Pressure Modulator Valve Bracket Replacement

Callout Component Name

Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM

with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM.

Preliminary Procedure

Turn the ignition switch to the OFF position.

Electronic Brake Control Module (EBCM) Electrical Connector

Procedure

1

1. Lift the locking tabs on the lower edge of the lever to release the electrical connector.

2. Position the electrical connector toward the front of the vehicle.

Brake Pressure Modulator Valve (BPMV) Bolt

2

Caution: Refer to Fastener Caution in the Preface section.

Tighten

11 N·m (97 lb in)

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BPMV Assembly

Procedure

3

4

5

1. Carefully separate the BPMV from the bracket. Do not pry on the accumulator covers on the underside of the BPMV.

2. Position the BPMV assembly upward and support with heavy mechanics wire or equivalent.

3. Do not remove the mounting pins unless it is necessary to aid in releasing the modulator assembly from the bracket.

BPMV Mounting Bracket Bolt (Qty: 3)

Tighten 10 N·m (89 lb in)

BPMV Mounting Bracket

Procedure

1. Inspect the BPMV bracket insulators for damage and replace, if necessary.

2. Use denatured alcohol on the BPMV mounting pins as an installation aid, if necessary.

2009 Pontiac Solstice

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SKY, Solstice (VIN M) Service Manual

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Brakes

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Antilock Brake System

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Repair Instructions

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Electronic Traction Control Switch Replacement

Callout Component Name

Caution: Refer to Fastener Caution in the Preface section.

Fastener Tightening Specifications: Refer to Fastener Tightening Specifications.

Preliminary Procedure

1. Remove the lower I/P extension panel. Refer to Instrument Panel Extension Trim Plate

Replacement.

2. Disconcert the electrical connector for the traction control switch.

Switch, Traction Control.

1

Tip Depress the retaining clip for the traction control switch before removing the switch.

2009 Pontiac Solstice

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SKY, Solstice (VIN M) Service Manual

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Brakes

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Antilock Brake System

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Repair Instructions

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Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement

Callout

Component Name

Preliminary Procedures

Remove the floor panel carpet. Refer to Floor Panel Carpet Replacement.

Vehicle Yaw Sensor Nut (Qty: 2)

Caution: Refer to Fastener Caution

1

Tighten 10 N·m (89 lb in)

Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Assembly

in the Preface section.

Procedure

2

1. Disconnect the electrical connection.

2. Perform the Diagnostic System Check - Vehicle.

3. Perform Steering Angle Sensor Calibration using Tech 2 Special Functions. Refer to Control

Module References

2009 Pontiac Solstice

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Specifications

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Body Repair

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Bolted Exterior Body Panels and Closures

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Fastener Tightening Specifications

Application

Battery Tray Bolts 31 N·m 23 lb ft Front Fender Bolts 10 N·m 89 lb in Hinge to Hood Nut 25 N·m 18 lb ft Hood Latch Bolts 25 N·m 19 lb ft Hood Striker Bolt 10 N·m 89 lb in Hood Striker Bolts 25 N·m 18 lb ft Wheelhouse Liner Bolts 10 N·m 89 lb in

Specification

Metric English

2009 Pontiac Solstice

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 1582849

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Body Repair

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Bolted Exterior Body Panels and Closures

|

Hood Bumper Replacement

Callout

Hood Bumper

Component Name

1

Tip Adjust as necessary. Clockwise rotation of the bumper will lower the hood; counterclockwise rotation will raise the hood.

2009 Pontiac Solstice

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2100447

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Hood Primary Latch Release Cable Replacement

Removal Procedure

1. Remove the hood latch. Refer to Hood Primary and Secondary Latch Replacement.

2. Remove the heat shield from the hood latch cable before install.

3. Release the hood latch release cable from the hood latch assembly.

4. Attach a length of mechanic's wire to the exterior end of the cable, and note the routing of the cable for later installation.

5. Release the retainers securing the cable to the inner fender.

6. Push the cable grommet through the cowl panel and into the interior of the vehicle.

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7. Remove the screws attaching the hood release handle to the knee bolster.

8. Remove the cable from the release handle.

9. Pull the cable the rest of the way through the cowl panel and out from behind the sound insulation.

10. Detach the mechanic's wire from the cable, leaving the wire in position for aid in installation of the cable.

11. Remove the cable from the vehicle.

Installation Procedure

1. Install the heat shield to the hood latch cable.

2. Attach the mechanic's wire to the exterior end of the cable.

3. Using the mechanic's wire as an aid, guide the cable underneath the sound insulation and pass the exterior portion of the cable through the cowl panel.

4. Install the cable to the release handle.

5. Seat the cable grommet to the cowl panel.

6. Install the release handle to the knee bolster.

Caution: Refer to Fastener Caution

7. Install the screws that retain the release handle to the knee bolster. Tighten the bolts to 2 N·m (18 lb in).

in the Preface section.

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8. Route the cable as previously noted.

9. Attach the cable to the retainers on the inner fender.

10. Install the cable to the hood latch assembly.

11. Install the hood latch. Refer to Hood Primary

and Secondary Latch Replacement.

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2158599

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Front Side Door Replacement

Callout

Component Name

Preliminary Procedures

1. Remove the right or left front fender. Refer to Front Fender Replacement.

2. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and

Enabling.

3. Remove the front door trim panel. Refer to Door Trim Panel Replacement.

Front Side Door Check Link Bolt

1

2

Caution: Refer to Fastener Caution in the Preface section.

Tighten

10 N·m (89 lb in)

Front Side Door Upper Hinge Bolt (Qty: 2)

Procedure

1. Remove the water deflector.

2. Support the door before removing the hinge bolts.

3. Disconnect the electrical connector, if equipped.

4. With the aid of an assistant, remove the door.

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Tighten 30 N·m (22 lb ft)

Front Side Door Lower Hinge Bolt (Qty: 2)

3

4

Tighten 30 N·m (22 lb ft)

Front Side Door Assembly

Procedure

When replacing the door it is necessary to transfer all of the internal components.

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2158600

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Front Fender Replacement

Callout Component Name

Front Fender Bolts (Qty: 3)

1

2 Front Fender Retainers (Qty: 3)

3

4

5

6 Front Fender

Caution: Refer to Fastener Caution in the Preface section.

Tighten

10 N·m (89 lb in)

Front Fender Bolt (Qty: 1)

Tighten 10 N·m (89 lb in)

Front Fender Bolt (Qty: 2)

Tighten 10 N·m (89 lb in)

Front Fender Bolt (Qty: 1)

Tighten 10 N·m (89 lb in)

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2100452

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Hood Primary Latch Release Cable Handle Replacement

Callout Component Name

Hood Latch Release Handle Screw (Qty: 2)

1

2

Caution: Refer to Fastener Caution in the Preface section.

Tighten

10 N·m (89 lb in) Hood Latch Release Handle

Tip Disconnect release cable.

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2158602

|

Body Repair

|

Bolted Exterior Body Panels and Closures

Front Side Door Upper Hinge and Lower Hinge

|

Replacement

Callout

Component Name

Front Side Door Upper Hinge Assembly Replacement

Front Side Door Hinge Upper Bolt (Qty: 2)

Caution: Refer to Fastener Caution in the Preface section.

1

Tip Replace only one hinge at a time.

Tighten 35 N·m (26 lb ft)

Front Side Door Hinge Upper Bolt (Qty: 2)

2

Tighten 25 N·m (18 lb ft)

Front Side Door Upper Hinge Assembly

Caution: Striker alignment is a crucial part of door latch operation. Do not use the door striker to adjust the door to the vehicle. Failure to properly adjust the striker

3

can result in damage to the door latch and the striker.

Tip Check the door for proper alignment, adjust as necessary.

Front Side Door Lower Hinge Assembly Replacement

Front Side Door Hinge Lower Bolt (Qty: 2)

Tip

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Replace only one hinge at a time.

4

Tighten 35 N·m (26 lb ft)

Front Side Door Hinge Lower Bolt (Qty: 2)

5

Tighten 25 N·m (18 lb ft)

Front Side Door Lower Hinge Assembly

Caution: Striker alignment is a crucial part of door latch operation. Do not use the door striker to adjust the door to the vehicle. Failure to properly adjust the striker

6

can result in damage to the door latch and the striker.

Tip Check the door for proper alignment, adjust as necessary.

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2100458

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Hood Hinge Replacement

Callout Component Name

Preliminary Procedure

1. Remove the hood. Refer to Hood Replacement.

2. Remove the hood strut rod. Refer to Hood Strut Replacement.

Hood Hinge Nut (Qty: 4)

1

2 Hood Hinge

Caution: Refer to Fastener Caution in the Preface section.

Tighten

25 N·m (18 lb ft)

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2158605

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Rear Compartment Lid Hinge Replacement

Callout Component Name

Preliminary Procedures

1. Remove the rear compartment lid. Refer to Rear Compartment Lid Replacement.

2. Remove the rear compartment torque rod. Refer to Rear Compartment Lid Hinge

Torque Rod Replacement.

Rear Compartment Lid Hinge Bolts (Qty: 2)

1

2 Rear Compartment Hinge

Caution: Refer to Fastener Caution in the Preface section.

Tighten

25 N·m (19 lb ft)

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2158606

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Hood Adjustment

Slotted holes are provided at the hood hinge attaching points for proper adjustment, both cross car, fore and aft, the rear corners to the doors and the fenders. Vertical adjustment at the front may be made by adjusting the rubber bumpers up and down. For best results, make one adjustment at a time.

Leading Edge of the Hood (Minor Up/Down Variation or Shake)

1. Determine the amount of adjustment needed.

2. Open the hood.

3. Raise or lower the vertical adjustment bumpers at the hood hinge to the specified height.

4. Inspect the hood alignment.

Fore and Aft Adjustment

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1. Determine the amount of adjustment needed.

2. Open the hood.

3. Loosen the hinge to hood bolts.

4. Reposition the hinge.

Caution: Refer to Fastener Caution

5. Tighten the hinge bolts.

Tighten Tighten to 25 N·m (19 lb ft).

6. Inspect the hood alignment.

Cross-Car Adjustment

in the Preface section.

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1. Determine the amount of adjustment needed.

2. Open the hood.

3. Loosen the hinge to hood hinge.

4. Reposition the hinge.

5. Tighten the hinge bolts.

Tighten Tighten to 25 N·m (19 lb ft).

6. Inspect the hood alignment.

Up/Down Adjustment Rear Edge of Hood (To Achieve Fit to the Doors and Fenders)

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1. Determine the amount of adjustment needed.

2. Open the hood.

3. Loosen the side hood latch.

4. Reposition the hood latch.

5. Tighten the hood latch bolts.

Tighten Tighten to 25 N·m (19 lb ft).

6. Inspect the hood alignment.

2009 Pontiac Solstice

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2158609

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Hood Replacement

Callout

Component Name

Preliminary Procedure

Remove the headlamps. Refer to Headlamp Replacement.

Hood Hinge Nuts (Qty: 4)

Tip

1. Disconnect the wiring harness from the hood on both sides.

1

2

2. Mark the hood for proper alignment for re-installing.

Caution: Refer to Fastener Caution in the Preface section.

Tighten

25 N·m (19 lb ft) Hood

Warning: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury.

2009 Pontiac Solstice

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 1582859

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Hood Insulator Replacement

Callout Component Name

1 Hood Insulator Retainers (Qty: 11) 2 Hood Insulator

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2100469

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Hood Primary and Secondary Latch Replacement

Callout Component Name

Hood Latch Bolt (Qty: 3)

1

2

Caution: Refer to Fastener Caution in the Preface section.

Tighten

25 N·m (19 lb ft) Hood Latch

Tip Disconnect the release cable.

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Compartment Lid

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2158614

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Rear Compartment Lid Replacement

Callout Component Name

Preliminary Procedures

1. Disconnect the rear compartment lid buttress latch release cable and pull it through the lid and set it aside with the pass-through grommet. Refer to Rear

Buttress Latch Release Cable Replacement.

2. Before installing the deck lid to the vehicle, apply a 6 mm bead of 3M® 08405 Flex Clear Seam Sealer or equivalent, to the upper interface joint of the seal flange to the deck lid inner (a).

Rear Compartment Lid Bolt (Qty: 4)

1

2

Caution: Refer to Fastener Caution in the Preface section.

Tighten

25 N·m (19 lb ft) Rear Compartment Lid

Tip Transfer any parts over to the new lid if needed.

2009 Pontiac Solstice

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2158617

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Front Side Door Check Link Replacement

Callout Component Name

Preliminary Procedures

1. Remove the interior trim panel. Refer to Door Trim Panel Replacement.

2. Remove the water deflector. Refer to Door Water Deflector Replacement.

3. Move the window to the full up position.

Front Side Door Check Link Bolt

1

2

3

Caution: Refer to Fastener Caution in the Preface section.

Tighten

10 N·m (89 lb in) Front Side Door Check Link Nut (Qty: 2)

Tighten 10 N·m (89 lb in)

Front Side Door Check Link Assembly

Tip Remove the check link from the inside of the door.

2009 Pontiac Solstice

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2150752

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Roof Panel Stiffener Replacement

Callout Component Name

Preliminary Procedure

Remove the roof panel rear extension. Refer to Roof Panel Rear Extension Replacement.

Roof Panel Stiffener Bolt (Qty: 2)

1

2 Roof Panel Stiffener

Caution: Refer to Fastener Caution in the Preface section.

Tighten

8 N·m (71 lb in)

2009 Pontiac Solstice

or a 50/50 mixture

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2150678

|

Body Repair

|

Bolted Exterior Body Panels and Closures

Roof Lift Off Panel/Window Rear Weatherstrip

|

Replacement

Callout

Roof Lift Off Panel/Window Rear Weatherstrip Screw (Qty :4)

Caution: Refer to Fastener Caution in the Preface section.

1

Tighten 2 N·m (18 lb in)

2 Roof Lift Off Panel/Window Rear Weatherstrip Retainer (Qty :2)

Roof Lift Off Panel/Window Rear Weatherstrip

Component Name

Procedure

3

1. Use a plastic flat-bladed tool to assist in the removal of the weatherstrips twoway tape from the body.

2. Clean the surface using a clean lint free cloth with naphtha of isopropyl alcohol and water to clean and remove the adhesive film.

3. Ensure the fit of the roof lift off panel/rear window weatherstrip to the weatherstrip retainers is correct before installing the two-way tape to the body and the retainers, to avoid water leaks.

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2150679

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Roof Panel Support Replacement

Callout Component Name

Preliminary Procedure

Remove the roof panel. Refer to Roof Panel Replacement.

Roof Panel Support Nut (Qty: 2)

1

2 Roof Panel Support

Caution: Refer to Fastener Caution in the Preface section.

Tighten

10 N·m (89 lb in)

2009 Pontiac Solstice

Compartment Front Trim

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2150782

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Roof Panel Replacement

Callout Component Name

Preliminary Procedures

1. Remove the roof panel rear extension. Refer to Roof Panel Rear Extension

Replacement.

2. Remove the rear compartment front trim panel. Refer to Rear

Panel Replacement.

3. Remove the rear end trim finish panel. Refer to Rear End Trim Finish Panel

Replacement.

4. Remove the rear compartment side trim panel. Refer to Rear

Panel Replacement.

5. Remove the rear end trim finish upper panel. Refer to Rear End Trim Finish Upper

Panel Replacement.

Roof Panel Nut (Qty: 3)

1

Caution: Refer to Fastener Caution in the Preface section.

Tighten

10 N·m (89 lb in)

Roof Panel Bolt (Qty: 4)

Compartment Side Trim

2

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Tighten 10 N·m (89 lb in)

Roof Panel Nut (Qty: 2)

3

4 Roof Panel

Tighten 10 N·m (89 lb in)

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2150717

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Roof Panel Rear Extension Replacement

Callout Component Name

Roof Panel Rear Extension Screw (Qty: 2)

1

2 Roof Panel Rear Extension Retainer (Qty: 6) 3 Roof Panel Rear Extension

Caution: Refer to Fastener Caution in the Preface section.

Tighten

5 N·m (44 lb in)

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2158620

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Fuel Tank Filler Door Replacement

Callout

Fuel Filler Door Rivets (Qty: 2)

1

Warning: Eye protection must be worn when drilling rivets to reduce the chance of personal injury.

2 Fuel Filler Door

Component Name

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2158623

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Fuel Tank Filler Pipe Housing Replacement

Callout Component Name

Fuel Filler Pocket Bolts (Qty: 3)

1

2 Fuel Filler Pocket

Caution: Refer to Fastener Caution in the Preface section.

Tighten

10 N·m (89 lb in)

2009 Pontiac Solstice

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2100493

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Hood Strut Replacement

Callout

1

Component Name

Hood Strut Assembly

Warning: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury.

Caution: Apply pressure only at the end of the liftgate/hood assist rod that you are removing or attaching. Do NOT apply pressure to the middle of the rod because damage or bending will result.

Tip Remove the metal clip at the ends of the assist rod, then pull away from stud.

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2158625

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Rear Compartment Lid Hinge Torque Rod Replacement

Callout Component Name

Warning: Refer to Rear Compartment Lid Hold-Open Device Warning in the Preface section.

Preliminary Procedure

Remove the rear fascia. Refer to Rear Bumper Fascia Replacement.

Rear Compartment Lid Torque Rods

Tip

1

1. Use tool J 39384-10 .

2. Install torque rods with rear compartment lid closed.

3. Engage the ends of the torque rods into the cam link.

4. Open deck lid and engage the fixed end into the hinges.

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 1582856

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Body Repair

|

Bolted Exterior Body Panels and Closures

|

Hood Rear Seal Replacement

Callout Component Name

Fastener Tightening Specifications: Refer to Fastener Tightening Specifications .

1 Weatherstrip, Rear Hood

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2100500

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Front Side Door Rear Weatherstrip Replacement

Callout

1

2

Component Name

Front Side Door Weatherstrip Rear Screw

Caution: Refer to Fastener Caution in the Preface section.

Tighten

2 N·m (18 lb in) Front Door Weatherstrip

Caution: Refer to Exterior Trim Emblem Removal Caution in the Preface section.

Procedure

1. The part and surface should be 21°C (70°F) prior to installation. The vehicle should remain 21°C (70°F) for one hour after assembly to allow adhesive to develop sufficient bond strength.

2. Use a J 25070 all adhesive from panel and wipe the surface dry with a clean lint-free towel prior to installing the new weatherstrip.

3. Apply 2 layers of adhesive tape.

4. When removing protective liners from the adhesive tape, be careful not to

Heat Gun or equivalent to remove the old weatherstrip. Clean

touch tape with hands and do not allow tape to come in contact with dirt or

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any foreign matter prior to adhesion.

5. Using the palm of the hand, wet out the weatherstrip to the panel and ensure full adhesion of the weatherstrip is made.

Special Tools

J 25070 Heat Gun

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 1742449

|

Body Repair

|

Bolted Exterior Body Panels and Closures

|

Front Door Opening Weatherstrip Replacement

Callout Component Name

Preliminary Procedure

Remove the interior trim panel. Refer to Door Trim Panel Replacement .

Front Door Opening Weatherstrip

1

Tip Pull the weatherstrip away from the door to release the retainers.

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 1742397

|

Body Repair

|

Bolted Exterior Body Panels and Closures

Rear Compartment Lid Weatherstrip Replacement

|

(Convertible)

Callout Component Name

1 Rear Compartment Lid Weatherstrip 2 Compartment Lid Weatherstrip (Rear)

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SKY, Solstice (VIN M) Service Manual

Repair Instructions

| Document ID: 2150649

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Body Repair

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Bolted Exterior Body Panels and Closures

Rear Compartment Lid Weatherstrip Replacement

|

(Coupe)

Callout Component Name

Preliminary Procedure

Remove the roof panel. Refer to Roof Panel Replacement.

1 Rear Compartment Lid Weatherstrip

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Repair Instructions

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Body Repair

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Bolted Exterior Body Panels and Closures

|

Rear Compartment Front Panel Replacement

Callout Component Name

Preliminary Procedure

1. Slide front seats forward and tilt seat back down.

2. Remove door sill trim. Refer to Door Sill Plate Replacement.

3. Remove lock pillar trim panel. Refer to Body

4. Remove the rear window panel trim. Refer to Rear Window Panel Trim Replacement.

5. Remove the front side door rear weatherstrip. Refer to Front Side Door Rear

Weatherstrip Replacement.

Rear Compartment Front Trim Panel Screw (Qty: 16)

1

2 Rear Compartment Front Trim Panel Assembly

Caution: Refer to Fastener Caution in the Preface section.

Tighten

2 N·m (18 lb in)

Lock Pillar Trim Panel Replacement.

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Document ID: 1956113

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Body Repair

|

Bumpers and Fascias

|

Repair Instructions

Front Bumper Fascia Energy Absorber Replacement

|

(Solstice)

Callout Component Name

Preliminary Procedure

Remove the front fascia. Refer to Front Bumper Fascia Replacement

1 Front Fascia Absorber Retainers (Qty: 4) 2 Front Fascia Absorber

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Document ID: 2158632

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Body Repair

|

Bumpers and Fascias

|

Repair Instructions

|

Front Bumper Impact Bar Replacement

Callout Component Name

Preliminary Procedures

1. Remove the front fascia. Refer to Front Bumper Fascia Replacement.

2. Remove the air deflector. Refer to Front Bumper Fascia Air Deflector Replacement.

3. Remove the energy absorber. Refer to Front

Replacement.

4. Remove the front bumper impact bar bracket. Refer to Front Bumper Impact Bar

Bracket Replacement.

Front Impact Bar Bolt (Qty: 8)

1

2

Caution: Refer to Fastener Caution in the Preface section.

Tighten

22 N·m (16 lb ft) Front Impact Bar Bolt (Qty: 4)

Tighten 9 N·m (80 lb in)

Front Impact Bar

Bumper Fascia Energy Absorber

Tip

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3

1. Disconnect the electrical harness from the impact bar.

2. Remove the hood adjusters from the impact bar, if required.

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Document ID: 2100650

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Body Repair

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Bumpers and Fascias

|

Repair Instructions

|

Front Bumper Impact Bar Bracket Replacement

Callout Component Name

Preliminary Procedure

Remove the front fascia. Refer to Front Bumper Fascia Replacement.

Center Front Fascia Support Bolt (Qty: 4)

1

2 Center Front Fascia Support Assembly

Caution: Refer to Fastener Caution in the Preface section.

Tighten

8 N·m (80 lb in)

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Document ID: 2158644

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Body Repair

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Bumpers and Fascias

|

Repair Instructions

|

Front Bumper Fascia Replacement (Solstice Base)

Callout Component Name

1 Front Fascia Retainers (Qty: 5) 2 Front Fascia Retainers (Qty: 10)

Wheelhouse Liner Screws (Qty: 6)

3

4

5

6

Caution: Refer to Fastener Caution in the Preface section.

Tighten

2 N·m (18 lb in) Front Fascia Bolts (Qty: 2)

Tighten 10 N·m (89 lb in)

Front Fascia Bolts (Qty: 2)

Tighten 10 N·m (89 lb in)

Front Fascia

Tip

Disconnect all electrical connectors.

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SKY, Solstice (VIN M) Service Manual

Document ID: 2158647

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Body Repair

|

Bumpers and Fascias

|

Repair Instructions

|

Front Bumper Fascia Replacement (Solstice Turbo)

Callout Component Name

Preliminary Procedure

Disconnect the brake cooling duct retainer. Refer to Front Brake Caliper Cooling Duct

Replacement.

1 Front Fascia Retainers (Qty: 5) 2 Front Fascia Retainers (Qty: 6)

Wheelhouse Liner Screws (Qty: 6)

3

4

5

Caution: Refer to Fastener Caution in the Preface section.

Tighten

2 N·m (18 lb in) Front Fascia Bolts (Qty: 2)

Tighten 10 N·m (89 lb in)

Front Fascia Bolts (Qty: 4)

Tighten

10 N·m (89 lb in)

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Front Fascia

6

Tip Disconnect all electrical connectors.

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SKY, Solstice (VIN M) Service Manual

Document ID: 2158649

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Body Repair

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Bumpers and Fascias

|

Repair Instructions

|

Front Bumper Fascia Support Replacement

Callout Component Name

Preliminary Procedures

1. Remove the front fascia. Refer to Front Bumper Fascia Replacement.

2. Remove the air deflector. Refer to Front Bumper Fascia Air Deflector Replacement.

Lower Front Fascia Support Bolts (Qty: 2)

1

2 Lower Front Fascia Support

Caution: Refer to Fastener Caution

Tighten

9 N·m (80 lb in)

in the Preface section.

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Document ID: 2158652

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Body Repair

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Bumpers and Fascias

|

Repair Instructions

|

Front Bumper Fascia Reinforcement Replacement

Callout

Component Name

Preliminary Procedure

Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.

Front Bumper Fascia Side Reinforcement Nuts (Qty: 3)

Caution: Refer to Fastener Caution in the Preface section.

1

Tighten 9 N·m (80 lb in)

Front Bumper Fascia Side Reinforcement Bolts (Qty: 2)

2

Tighten 9 N·m (80 lb in)

Front Bumper Fascia Side Reinforcement

3

Tip Remove the screws from the end of the fascia and then remove the reinforcement.

Front Bumper Fascia Brace Bolt (Qty: 1)

Tighten

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4

9 N·m (80 lb in)

5 Front Bumper Fascia Brace

Front Bumper Fascia Outer Support Bolt (Qty: 1)

6

Tighten 9 N·m (80 lb in)

7 Front Bumper Fascia Outer Support

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Document ID: 1582624

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Body Repair

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Bumpers and Fascias

|

Repair Instructions

|

Front Bumper Fascia Air Deflector Replacement

Callout Component Name

Fastener Tightening Specifications: Refer to Fastener Tightening Specifications .

1 Retainers, Front Air Deflector (Qty: 12) 2 Air Deflector, Front

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Document ID: 1746939

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Body Repair

|

Bumpers and Fascias

|

Repair Instructions

|

Rear Bumper Extension Replacement

Callout Component Name

Preliminary Procedure

1. Remove the rear fascia. Refer to Rear Bumper Fascia Replacement .

2. Remove the back up lamp.

Rear Fascia Extension

1

Tip Release tabs to remove.

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Document ID: 2158658

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Body Repair

|

Bumpers and Fascias

|

Repair Instructions

|

Rear Bumper Fascia Replacement (Solstice)

Callout Component Name

Preliminary Procedure

• Remove both fender liner sides. Refer to Rear Wheelhouse Panel Liner Replacement.

• Remove the tail lamps. Refer to Tail Lamp Replacement.

• Remove the high mount stop lamp. Refer to High Mount Stop Lamp Replacement.

• Remove the backup lamps. Refer to Backup Lamp Replacement.

• Remove the license lamp. Refer to Rear License Lamp Replacement. 1 Rear Fascia Retainers (Qty: 6)

2 Rear Fascia Retainers (Qty: 6)

Rear Fascia Bolts (Qty: 6)

3

4

5 Rear Fascia

Caution: Refer to Fastener Caution in the Preface section.

Tighten

10 N·m (89 lb in) Rear Fascia Bolts (Qty: 8)

Tighten 10 N·m (89 lb in)

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Body Repair

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Bumpers and Fascias

|

Repair Instructions

|

Rear Bumper Fascia Center Bracket Replacement

Callout Component Name

Preliminary Procedures

1. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.

2. Remove the rear bumper fascia bracket. Refer to Rear Bumper Fascia Bracket

Replacement.

Rear Bumper Fascia Center Bracket Nut (Qty: 4)

1

2 Rear Bumper Fascia Center Bracket

Caution: Refer to Fastener Caution in the Preface section.

Tighten

3 N·m (17 lb in)

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Body Repair

|

Bumpers and Fascias

|

Repair Instructions

|

Rear Bumper Lower Fascia Retainer Replacement

Callout Component Name

Preliminary Procedure

Remove the rear fascia lower retainer. Refer to Rear Bumper Fascia Replacement.

Rear Bumper Lower Retainer Screw (Qty: 4)

1

2 Rear Bumper Fascia Lower Retainer

Caution: Refer to Fastener Caution in the Preface section.

Tighten

9 N·m (80 lb in)

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Body Repair

|

Bumpers and Fascias

|

Repair Instructions

|

Rear Bumper Fascia Outer Support Replacement

Callout Component Name

Preliminary Procedure

Remove the rear fascia. Refer to Rear Bumper Fascia Replacement.

Rear Fascia Support Outer Screw (Qty: 4)

1

2 Rear Fascia Push Pin (Qty: 2) 3 Rear Fascia Support

Caution: Refer to Fastener Caution in the Preface section.

Tighten

17 N·m (13 lb ft)

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SKY, Solstice (VIN M) Service Manual

Document ID: 2100645

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Body Repair

|

Bumpers and Fascias

|

Repair Instructions

|

Rear Bumper Fascia Support Bracket Replacement

Callout Component Name

Preliminary Procedure

Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.

Rear Bumper Fascia Support Bracket Screw (Qty: 4)

1

2 Rear Bumper Fascia Support Bracket

Caution: Refer to Fastener Caution in the Preface section.

Tighten

9 N·m (25 lb in)

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SKY, Solstice (VIN M) Service Manual

Document ID: 2100646

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Body Repair

|

Bumpers and Fascias

|

Repair Instructions

|

Rear Bumper Fascia Bracket Replacement

Callout Component Name

Preliminary Procedure

Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.

Rear Fascia Bracket Bolt (Qty: 3)

1

2

3 Rear Fascia Bracket

Caution: Refer to Fastener Caution in the Preface section.

Tighten

9 N·m (80 lb in) Rear Fascia Bracket Nut (Qty: 4)

Tighten 17 N·m (13 lb ft)

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Body Repair

|

Bumpers and Fascias

|

Repair Instructions

|

Rear Energy Absorber Replacement (Solstice)

Callout Component Name

Fastener Tightening Specifications: Refer to Fastener Tightening Specifications .

Preliminary Procedure

Remove the rear fascia. Refer to Rear Bumper Fascia Replacement

1 Absorber

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Document ID: 1581399

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Brakes

|

Disc Brakes

|

Specifications

|

Fastener Tightening Specifications

Application

Brake Caliper Bleeder Valve - Front 11 N·m 97 lb in Brake Caliper Bleeder Valve - Rear 14 N·m 10 lb ft Brake Caliper Bracket Bolt - Front and Rear 115 N·m 85 lb ft Brake Caliper Guide Pin Bolt - Front 34 N·m 25 lb ft Brake Caliper Guide Pin Bolt - Rear 27 N·m 20 lb ft Brake Hose Fitting Bolt - Front and Rear 40 N·m 30 lb ft Brake Rotor Screw - Front and Rear 10 N·m 89 lb in

Specification

Metric English

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Brakes

|

Disc Brakes

|

Specifications

|

Disc Brake Component Specifications

Specification

Application

Metric English

Front Brakes

Brake Rotor Diameter 296.00 mm 11.653 in

l l

Brake Rotor Discard Thickness* 23.0 mm 0.906 in Brake Rotor Maximum Allowable Assembled Lateral

l

Runout Brake Rotor Maximum Allowable Scoring 1.50 mm 0.059 in

l l

Brake Rotor Maximum Allowable Thickness Variation 0.025 mm 0.001 in Brake Rotor Minimum Allowable Thickness After

l

Refinish Brake Rotor Thickness - New 26.0 mm 1.023 in

l

0.06 mm 0.002 in

23.5 mm 0.925 in

Rear Brakes

Brake Rotor Diameter 278.0 mm 10.945 in

l

Brake Rotor Discard Thickness* 10.0 mm 0.394 in

l

Brake Rotor Maximum Allowable Assembled Lateral

l

Runout Brake Rotor Maximum Allowable Scoring 1.50 mm 0.059 in

l

Brake Rotor Maximum Allowable Thickness Variation 0.025 mm 0.001 in

l

Brake Rotor Minimum Allowable Thickness After

l

Refinish Brake Rotor Thickness - New 11.8 mm 0.465 in

l

0.06 mm 0.002 in

10.5 mm 0.413 in

* All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this specification. After refinishing the rotor, replace any rotor that does not meet the minimum thickness after refinish specification.

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Brakes

|

Disc Brakes

|

Repair Instructions

|

Front Disc Brake Pads Replacement

Callout

Warning: Refer to Brake Dust Warning in the Preface section.

Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is

separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

Component Name

Preliminary Procedures

1. Inspect the fluid level in the brake master cylinder reservoir.

2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.

3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.

4. Raise and support the vehicle. Refer to Lifting

5. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and

Installation.

Brake Caliper Guide Pin Bolt

and Jacking the Vehicle.

Caution: Refer to Fastener Caution in the Preface section.

and inspect the

springs. Install NEW

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Tip Only remove the lower brake caliper guide pin bolt.

1

Tighten 34 N·m (25 lb ft)

Brake Caliper Assembly

Tip

• Without disconnecting the brake hose, pivot the brake caliper upward and

2

3 Brake Pad (Qty: 2)

support with heavy mechanics wire or equivalent.

• Place a block of wood or an old disc brake pad against the brake caliper piston.

• Using a large C-clamp, slowly and evenly compress the brake caliper piston squarely into the caliper bore.

Brake Pad Spring

Procedure

4

1. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket of any debris and corrosion.

2. Inspect the brake caliper guide pins for freedom of movement condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores without disengaging the slides from the boots and observe for the following:

• Restricted caliper guide pin movement

• Looseness in the brake caliper mounting bracket

• Seized or binding caliper guide pins

• Split or torn boots

3. If any of the conditions are found, the brake caliper guide pins and/or boots require replacement.

4. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket only.

5. If replacing the brake pads, DO NOT reuse the brake pad brake pad springs.

6. After the installation is complete, with the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.

7. Slowly release the brake pedal.

8. Wait 15 seconds, then repeat steps 6-7 until a firm brake pedal is obtained. This will properly seat the brake caliper piston and brake pads.

9. Fill the master cylinder reservoir to the proper level. Refer to Master

Reservoir Filling.

10. Burnish the brake pads and rotors. Refer to Brake Pad and Rotor Burnishing.

Cylinder

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Brakes

|

Disc Brakes

|

Repair Instructions

|

Rear Disc Brake Pads Replacement

Callout

Warning: Refer to Brake Dust Warning in the Preface section.

Component Name

Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is

separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

Preliminary Procedures

1. Inspect the fluid level in the brake master cylinder reservoir.

2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.

3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.

4. Raise and support the vehicle. Refer to Lifting

5. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and

Installation.

1 Brake Caliper Spring 2 Brake Caliper Guide Pin Bushing Seal (Qty: 2)

Brake Caliper Guide Pin (Qty: 2)

Caution: Refer to Fastener Caution in the Preface section.

3

and Jacking the Vehicle.

Tighten 27 N·m (20 lb ft)

Disc Brake Caliper Assembly

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Caution: When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 in) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism.

4

Tip

• Use a large C-clamp to compress the brake caliper piston slightly to ease caliper removal. DO NOT exceed 1 mm (0.039 in) of caliper piston travel.

• Using a spanner type tool or equivalent, rotate the brake caliper piston clockwise while applying slight inward pressure to retract the piston into the caliper.

• Without disconnecting the brake hose position the brake caliper aside and support with heavy mechanics wire or equivalent.

Disc Brake Pad - Inner

5

Tip Ensure the brake pad equipped with the spring is installed facing the inner friction surface of the brake rotor.

Disc Brake Pad - Outer

Procedure

6

1. Thoroughly clean the brake pad mating surfaces of the caliper bracket of any debris and corrosion.

2. Inspect the brake caliper guide pins for freedom of movement and inspect the condition of the guide pin bushings. Move the guide pins in and out within the bushings and observe for the following:

• Restricted caliper guide pin movement

• Seized or binding caliper guide pins

• Split or torn bushings

3. If any of the conditions listed are found, the brake caliper guide pins and/or bushings require replacement.

4. After the installation is complete, with the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.

5. Slowly release the brake pedal.

6. Wait 15 seconds, then repeat steps 4-5 until a firm brake pedal is obtained. This will properly seat the brake caliper piston and brake pads.

7. Fill the master cylinder to the proper level. Refer to Master

Filling.

8. Burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing.

Cylinder Reservoir

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Brakes

|

Disc Brakes

|

Repair Instructions

|

Brake Pad and Rotor Burnishing

Warning: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not

attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage.

Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system.

This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced.

1. Select a smooth road with little or no traffic.

2. Accelerate the vehicle to 48 km/h (30 mph).

Note: Use care to avoid overheating the brakes while performing this step.

3. Using moderate to firm pressure, apply the brakes to bring the the brakes to lock.

4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors.

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SKY, Solstice (VIN M) Service Manual

Document ID: 2101261

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Brakes

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Disc Brakes

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Repair Instructions

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Front Brake Caliper Replacement

Callout

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Component Name

Warning: Refer to Brake Dust Warning in the Preface section.

Preliminary Procedures

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation. Brake Hose Fitting Bolt

Caution: Refer to Fastener Caution in the Preface section.

1

Tighten 40 N·m (30 lb ft)

Brake Hose Fitting Gasket (Qty: 2)

2

Tip DO NOT reuse the brake hose fitting gaskets. Install NEW gaskets.

Front Brake Hose

3

Tip Plug the brake hose fitting to prevent brake fluid loss and contamination.

Brake Caliper Guide Pin Bolt (Qty: 2)

4

Tighten 34 N·m (25 lb ft)

Brake Caliper

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Procedure

5

1. If any of the disc brake caliper hardware is found to have excessive wear, replace the hardware. Refer to Front Disc Brake Hardware Replacement.

2. Bleed the hydraulic brake system. Refer to Hydraulic

3. After the installation is complete and with the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.

4. Slowly release the brake pedal.

5. Wait 15 seconds, then repeat steps 3-4 until a firm brake pedal is obtained. This will properly seat the brake caliper piston and the brake pads.

6. Fill the master cylinder to the proper level. Refer to Master

Filling.

7. Burnish the pads and rotors. Refer to Brake

Pad and Rotor Burnishing.

Brake System Bleeding.

Cylinder Reservoir

2009 Pontiac Solstice

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2/22/2010

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SKY, Solstice (VIN M) Service Manual

Document ID: 2101262

|

Brakes

|

Disc Brakes

|

Repair Instructions

|

Rear Brake Caliper Replacement

Callout

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Warning: Refer to Brake Dust Warning in the Preface section.

Note: New brake calipers are packaged filled with brake fluid. DO NOT drain the brake fluid

from the new caliper prior to installation. Draining the brake fluid from the new brake caliper will prevent the brake caliper from bleeding properly.

Component Name

Preliminary Procedures

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and

Installation.

3. Release the tension from the park brake cables. Refer to Park Brake Adjustment.

4. Disconnect the park brake cable from the actuator lever on the brake caliper.

Brake Hose Fitting Bolt

Caution: Refer to Fastener Caution in the Preface section.

Tip

Pontiac Solstice 2010 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual